MASSEY FERGUSON MF-2400 UTILITY SERIES MF-2430 MF-2435 MF-2440 TRACTOR SERVICE MANUAL – PDF Download by www.heydownloads.com

MF 2430 - 2435 - 2440

WORKSHOP MANUAL P/N 3681774M1 - EDITION 01-2006

MASSEY FERGUSON

INTRODUCTION This manual refers to the MF 2430 - 2435 - 2440 tractor manufactured by MF. It is divided into sections identified by numbers with three/four figures. The pages of each section are numbered separately. - The subjects described are listed in the general index and appear in more detail in the specific index of the section in question. - The date of the relative edition/update is printed at the bottom of each page. - Pages where future updates are made will have the same printed number but the new date of issue. These pages will be supplied by a reprint of the duly updated index. - The information in this manual was up to date on the date printed on the page. Since MF constantly updates its range of products, some of the information could no longer be up to date following modifications made for technical or commercial reasons, or to adapt the machines to the laws in force in the various countries of use. Consult our Dealers and Assistance Centres if discrepancies are found.

LIABILITY MF declines all liability for incorrect servicing operations, use of spurious spare parts and tampering with parts of the product. The person in charge of the personnel is responsible for ensuring that the safety regulations described in the manual are applied. This person must be qualified to carry out the operations required, be familiar and strictly comply with the prescriptions in this manual and the general safety regulations applicable. Failure to comply with the safety regulations may lead to persons being injured and damage to machine components.

PURPOSE OF THE MANUAL This manual is mainly dedicated to workshop staff. This manual contains all the necessary technical information concerning the machine, allowing the servicing technicians to work in safety and guarantee that the product remains perfectly efficient throughout its working life. However, it is not a substitute for thorough professional training. To correctly carry out the servicing activities, it is assumed that the place of work conforms to the current standards governing safety and hygiene. This manual contains all the information required to correctly carry out modifications, tune ups, repairs and overhauls. Read this manual carefully before proceeding with any work. Correct repairs are guaranteed and the operators safeguarded from accidents by compliance with the instructions supplied and by using the right tools.

COPYRIGHT This publication may neither be fully nor partly duplicated in any form without the prior authorisation of MF. The illustrations and descriptions in this publication are purely indicative. The Manufacturer reserves the right, at any moment, to make any modifications to the machines considered necessary for improvement purposes or for manufacturing and marketing requirements, without being obliged to give prior notice.

MASSEY FERGUSON PRINTED MATERIAL S/N 3681774M1 EDITION 01-2006 WRITTEN BY SST s.r.l. - TORINO

P/N 3681774M1

Edition 01-2006

TABLE OF CONTENTS Section N° 1

Edition

GENERAL INFORMATION General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

01-2006

ENGINE Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

01-2006

CLUTCH Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300

01-2006

GEARBOX Speedfive and Powerfive mechanical gearbox . . . . . . . . . . . . . . . . . . 400

01-2006

TRANSMISSION Rear axle and side final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500 Front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510

01-2006 01-2006

POWER TAKE-OFF Power take-off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600

01-2006

HYDRAULIC SYSTEMS Hydraulic systems - Rear power lift. . . . . . . . . . . . . . . . . . . . . . . . . . 700

01-2006

STEERING Steering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800

01-2006

BRAKES Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900

01-2006

10 ELECTRICAL SYSTEMS Electrical system - Instruments . . . . . Electrical system - Components . . . . . Electrical system – Ignition system . . . Electrical system – Recharging system Electrical system - Battery . . . . . . . . . Electrical system – Electrical circuits . .

. 1000 . 1010 . 1020 . 1030 . 1040 . 1050

01-2006 01-2006 01-2006 01-2006 01-2006 01-2006

11 CAB Cab and A/C system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100

01-2006

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P/N 3681774M1

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SECTION 100 GENERAL INFORMATION

SECTION 100 - GENERAL INFORMATION TABLE OF CONTENTS Description

Page

SAFETY NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Personal risk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Avoid accidents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheels and tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Unhitching and re-hitching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100-3 100-3 100-3 100-3 100-5 100-5 100-5 100-5 100-6 100-6

GENERAL INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjuster shims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spinning shaft seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . O-ring toroid seals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Spring pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Notes about spare parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SPECIFIC EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100-7 100-7 100-7 100-7 100-7 100-7 100-7 100-8 100-8

SYMBOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-9 Meaning and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-9 DANGER SIGNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-11 Positions of the danger decals - WEO markets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-11 SEALING AND FIXING SEALANTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-16 LUBRICANTS AND FUELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-17 CONVENTIONAL UNITS OF MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18 Units of measurement (international system) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18 Conversion values for Imperial measurement system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-18 STANDARD DRIVING TORQUE VALUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-19 Screws with metric threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-19 Nuts with metric threads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100-20

100-2

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SECTION 100 - GENERAL INFORMATION

SAFETY NOTES Personal risk This warning symbol draws your attention to messages that are important for your safety. Read the safety notes carefully and comply with the recommended precautions to avoid potential dangers and safeguard your health and personal safety. This symbol appears in the text along with the following key words: WARNING - To warn of unsuitable repair operations with potential consequences that could affect the repair technician’s safety. DANGER - To indicate warnings that specifically denote potential dangers for the operator’s safety or for other directly or indirectly involved persons.

2LA0663

Avoid accidents The majority of accidents that occur in workshops are caused by failure to comply with some simple and fundamental rule of caution and safety. Therefore IN MOST CASES THEY CAN BE AVOIDED: all that’s needed is to foresee the possible causes and consequently act with due care and caution. However well a machine is designed and built, it is never possible to absolutely exclude all hazardous situations. A careful and prudent mechanic is the best guarantee against accidents. Strict compliance with even only one elementary safety rule would be sufficient to avoid many serious accidents. DANGER. Never carry out any cleaning, lubricating or servicing operations whilst the engine is running. General rules - Carefully comply with the prescribed maintenance and repair procedures. - Do not wear rings, watches, jewellery, unfastened or hanging garments, such as ties, torn clothing, scarves, unbuttoned jackets or with open zip-fasteners that could become caught in moving parts. You are advised to wear approved safety garments, such as: non-slip footwear, gloves, safety goggles, helmets, etc. - Never carry out repair work on the machine whilst someone is sitting in the driver’s seat, unless this person is an authorized operator who is helping with the operations in progress. - Only operate the machine and use the relative implements when you are sitting in the driver’s seat. - Do not carry out any work on the machine when the engine is running, unless this is specifically prescribed. - Stop the engine and make sure that the pressure has been relieved from the hydraulic circuits before removing any caps, covers, valves, etc. - All servicing work must be carried out with the utmost care and attention. - Ladders and platforms used in workshops or in the field must comply with the current safety regulations. - Disconnect the batteries and label all the controls to warn others that work is being carried out. Block the machine and all implements that must be raised. - Do not check or fill fuel tanks, batteries, or use ignition fluid when smoking or near naked flames as these liquids are inflammable. - The brakes are disengaged when released by hand for servicing work: in these cases, the machine must be kept under control by means of chocks or similar.

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SECTION 100 - GENERAL INFORMATION -

100-4

The fuel pump nozzle must always remain in contact with the filler. Keep it there until you finish filling so as to prevent sparks from being created through an accumulation of static electricity. Only use the prescribed hitching points when towing. Make the connections with care: make sure that the provided pins and/or latches are firmly fixed in place before beginning to tow. Keep well away from tow bars, ropes or chains that are pulling a load. If possible, use a trailer or truck with a lowered loading platform when transferring a faulty machine. When a machine must be loaded on to or unloaded from the transport vehicle, choose flat ground able to provide a solid bearing surface for the wheels of the trailer or truck. Fasten the machine to the truck or trailer platform firmly and block the wheels as required by the haulage contractor. Only use auxiliary power sources with grounding circuits able to prevent electric shocks from electric heaters, battery chargers and similar equipment. Use hoists and similar equipment with an adequate carrying capacity if heavy parts must be lifted or transported. Pay particular attention to bystanders. Never pour petrol or diesel fuel into wide and shallow open vessels. Never use petrol, diesel fuel or other inflammable fluids as detergents: use the non-flammable and nontoxic solvents available in the shops. Protect your eyes by wearing goggles with side guards when using compressed air to clean parts. Limit the pressure to 2.1 bars at most, in compliance with the local or national laws in force. Do not run the engine in a closed room without adequate ventilation. Do not smoke, use naked flames or create sparks in the vicinity when refuelling or handling easily inflammable materials. Do not use flames as a means of lighting when repairing the machine or searching for "leaks". Move with the greatest care when working under, on or near the machine. Wear approved safety garments such as helmets, goggles and safety footwear. When the engine must be running in order to make the inspections, ask for help from an operator who must remain in the driverâ&#x20AC;&#x2122;s seat and keep the mechanic under visual control at all times. If servicing is required away from the workshop, park the machine on flat ground and block it. If work on slopes is unavoidable, block the machine and move it to a horizontal surface as soon as this can be done within a certain safety margin. Do not use crushed or bent chains or ropes when lifting or towing are required. Always wear suitably thick gloves to handle them. Chains must be firmly fixed in place: make sure that the fastening is sufficiently strong to bear the load in question. Have all bystanders move well clear of the connection, chains or ropes used for lifting or towing. The area where the servicing operations are carried out must always be kept CLEAN and DRY. Puddles or water or oil stains must be cleaned up immediately. Do not form heaps of rags soaked in grease or oil: they could catch fire very easily. Always put them in a closed metal container. Check, regulate and lock the driverâ&#x20AC;&#x2122;s seat before starting the machine or implements. Make sure that there are no bystanders within the range of action of the machine or implements. Do not carry objects that could drop unseen into the internal mechanisms of the machine, in your pockets. Wear goggles with side guards, helmets, special safety footwear and gloves when you could be struck by metal objects and similar, thrown up during the servicing work. Use the necessary safety protections when welding operations are carried out: dark glasses, helmets, dungarees, special gloves and footwear. Dark glasses should also be worn by the people not actually doing the work but who are in the vicinity when welding is being carried out. NEVER LOOK AT THE WELDING ARC WITHOUT ADEQUATE EYE PROTECTION. Metal ropes become frayed with wear: always protect yourself in an adequate way when handling them (wear gloves, goggles, etc.).

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SECTION 100 - GENERAL INFORMATION -

Handle all parts with the utmost care. Keep your hands and fingers well away from gaps, wheelwork and similar. Always use approved personal protection devices such as safety goggles, gloves and safety footwear. Before you get on to the tractor, it is essential for you to have read and strictly complied with the instructions in the operation and maintenance manual.

Starting Engine -

Do not allow the engine to run in a closed room without adequate ventilation systems able to dispose of the exhaust gas. Never put your head, body, limbs, feet, hands or fingers near spinning fans or belts.

Before removing the radiator plug completely, turn it very slowly to relieve the pressure in the circuit. Coolant fluid must only be topped up with the engine at a standstill or idling, if hot. Do not refuel whilst the engine is running, particularly if it is hot. This could lead to the risk of a fire outbreak if fuel were to be spilt. Do not attempt to check or adjust the tension of the fan belts with the engine running. Do not regulate the fuel injection pump whilst the machine is on the move. Never lubricate the machine when the engine is running.

Electrical systems - If auxiliary batteries must be used, remember that the cables must be connected in the prescribed way at both ends: (+) with (+) and (-) with (-). Do not short-circuit the terminals. THE GAS ISSUED BY BATTERIES IS HIGHLY INFLAMMABLE. Always leave the battery compartment uncovered when recharging, to ensure a more efficient ventilation. Never ever check the battery charge using the "jumpers" obtained by placing metal objects on the terminals. Prevent sparks or flames in the battery area. Do not smoke as this could cause explosions. - Before proceeding with any work, make sure that there are no fuel or electricity leaks: repair these leaks before proceeding. - Do not recharge batteries in closed places: make sure that there is adequate ventilation to prevent accidental explosions from occurring due to an accumulation of the gas issued when recharging. - Always disconnect the batteries before working on the electrical system. Hydraulic circuits - Fluid leaking from a very small hole can be almost invisible yet have sufficient force to penetrate under the skin. Use a piece of cardboard or wood if you must check for such leaks. NEVER CHECK FOR LEAKS WITH THE HANDS: immediately seek medical help if fluid penetrates under the skin. Serious infections or dermatitis may occur if you fail to receive prompt medical treatment. - Use the right tools to check the pressure in the circuits.

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SECTION 100 - GENERAL INFORMATION Wheels and tyres - Make sure that the tyres are correctly inflated to the pressure indicated by the manufacturer. Periodically check the rims and tyres to make sure that they are not damaged. - Keep to the side of the tyre when correcting the inflation pressure. - Only check the pressure with the machine unloaded and the tyres cold, to prevent incorrect measurements and overpressures. Do not reuse repaired wheel parts as badly made welds, brazing or heating could have weakened them and cause breakage. - Never cut or weld a rim with a tyre mounted and inflated. - Block the machine at the front and rear on all wheels before demounting these latter. After you have jacked up the machine, prevent it from dropping by placing supports underneath, in compliance with the current laws in force. - Deflate the tyres before removing any objects jammed between the treads. - Never inflate the tyres with inflammable gas. This could lead to explosions and injure bystanders. Unhitching and re-hitching - Lift and handle all heavy parts with lifting equipment of an adequate capacity. Make sure that the parts are supported by appropriate harness and hooks. Use the lifting eyelets provided. Take care of bystanders near the load being lifted. - Handle all parts with the utmost care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. - Do not twist metal ropes or chains. Always wear safety gloves when handling cables or chains.

100-6

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SECTION 100 - GENERAL INFORMATION

GENERAL INSTRUCTIONS IMPORTANT WARNING All the maintenance operations and repairs described in this manual must be carried out by the MF assistance network only, in strict compliance with the indications given and using special tools if necessary. Anyone who carries out the described operations without strictly complying with the instructions becomes personally responsible for any consequent damage. Battery Before proceeding with any work, disconnect and insulate the negative battery cable unless other instructions are given for the specific operation required (for example: an operation where the engine must be running). After the operation has been terminated, detach this cable in order to finish the work. Adjuster shims Whenever adjustments are made, select the adjuster shims by measuring them one by one with a micrometre and then adding the values gauged: do not trust in the erroneous measurement of the complete pack or in the nominal value given for each ring. Spinning shaft seals Comply with the following instructions to correctly mount the spinning shaft seals: - before they are mounted, allow the seals to soak for at least half an hour in a bath of the same type of oil as that they will be sealing; - thoroughly clean the shaft and make sure that its operating surfaces are not damaged; - position the sealing lip towards the fluid. If the lip is the hydrodynamic type, the direction in which the scoring points (considering the direction in which the shaft spins) must tend to make the fluid flow towards the internal part of the seal; - spread a film of lubricant (oil is preferable to grease) on the sealing lip and fill the gap between the sealing lip and dust guard lip of double-lipped seals with grease; - fit the seal into its housing by pressing or use a punch with a flat contact surface. Never hit the seal with a hammer or mallet; - when a seal is mounted, make sure that it is inserted perpendicular to its housing. After mounting, make sure that it touches the supporting ridge (if applicable); - to prevent the seal lip from being damaged by the shaft, fit an adequate guard whilst the two parts are being assembled. O-ring toroid seals Lubricate the o-ring seals before they are fitted into their housings to prevent them from rolling around themselves and becoming twisted as they are mounted, something that would compromise their sealing ability. Bearings It is advisable to proceed in the following way when mounting bearings: - heat them to 80 â&#x2C6;&#x2019; 90 Â°C before fitting them on to their respective shafts; - cool them before externally fitting them into their housings. Spring pins When mounting split tube spring pins, make sure that their notches point in the direction of the force exercised on the pin itself. Spiral spring pins do not need to be set in any direction when mounted

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100-7

SECTION 100 - GENERAL INFORMATION Notes about spare parts Only use genuine MF spare parts as only these are able to guarantee the same quality, life and safety as the original components mounted on your machine. Only genuine MF spare parts can provide this guarantee. Give the following information when ordering spare parts: - tractor model (commercial denomination) and chassis number; - engine type and number; - order number of the required part, which can be found in the "Spare Parts Catalogue", according to which the orders are fulfilled. SPECIFIC EQUIPMENT The equipment that MF proposes and illustrates in this manual is: - explicitly researched and designed for work on MF tractors; - necessary for reliable repairs; - carefully made and thoroughly tested to provide efficient and long-lasting tools. Repairers should also remember that using the right equipment means: - working in technically optimum conditions; - obtaining the best result; - saving time and effort; - working in greater safety.

100-8

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SECTION 100 - GENERAL INFORMATION

SYMBOLS Meaning and use Certain symbols are used in this manual to underline and draw the readerâ&#x20AC;&#x2122;s attention to certain particular aspects of the description, or to indicate the type of operation being illustrated. The meanings of the various symbols used are described in the table below. SYMBOL

MEANING

NOTES

Warning: personal risk

Indicates a danger with the risk of even mortal accident for the user. Pay the utmost attention to the texts indicated with this symbol.

Warning: environmental hazard

Indicates a danger with the risk of damage to the natural environment. Pay the utmost attention to the texts indicated with this symbol.

Caution

Warns that the machine or some other personal property of the user could be damaged.

Note

Indicates a warning, a note about key functions or some other useful information.

Prevent damage to material

This indication means that there is a considerable risk of damage to a part, e.g. when the wrong tool is used or an assembly made by means of an incorrect procedure.

Special tool/ specific equipment

A special tool or specific equipment must be used for the operations.

Visual observation

A visual inspection must be made. The user must read a measurement value, check an indication, etc...

Listen

The operator must listen to a noise made when the machine operates. The inspection serves to identify abnormal noise.

Tighten and torque

Symbol associated with a value: use a torque wrench to suit the value given and measure the dwell angle at that torque value.

Torquing with angle

Symbol associated with two values: use a torque wrench to suit the value given and measure the dwell angle at that torque value.

Adjustment/Regulation

Operation carried out in order to obtain precise values (pressure, preload, relative distance, etc.).

Measuring/Gauging

Operation carried out in order to measure required to restore optimum functional conditions in the correct way.

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SECTION 100 - GENERAL INFORMATION

SYMBOL

MEANING

NOTES

Lubrication

Lubrication (oiling, greasing, etc...) of a part/ device.

Sealing/Gluing

Sealant required in order to couple two parts together.

Positioning

MF Spares.

100-10

Coupling with relative position references.

Indicates that only MF spare parts must be used.

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SECTION 100 - GENERAL INFORMATION

DANGER SIGNS If a tractor part bearing a decal with a safety note (yellow colour) is replaced, it is ESSENTIAL to affix the same decal to the spare part. A complete list of all the places where decals are applied is given below. Positions of the danger decals - WEO markets

17 7

8 16

12 13

4LA0129

Positions of the danger decals Complete set of danger decals N. 3559 552 M95

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SECTION 100 - GENERAL INFORMATION

REF.

100-12

CODE

POSITION

DESCRIPTION

3559 556 M1

On the left and right sides of the radiator or manifold.

WARNING: Danger of entanglement. Keep your hands well clear of the fan blades when the engine is running. Always keep the guards and screens mounted.

On both sides of the radiator.

WARNING: Danger of entanglement. Keep your hands well clear of spinning parts. Take care not to become entangled in the belts or pulleys whilst the engine is running. Keep the guards in place.

Near the brake circuit oil reservoir.

WARNING: Risk of damage to the brake circuit. Carefully read the danger warnings and the instructions shown in the operation and maintenance manual before starting maintenance operations.

On the starter motor.

WARNING: Electric shock. Always disconnect the negative battery terminal before removing the cover of the solenoid and before servicing the electrical system.

On the starter motor.

DANGER: Danger of being crushed. DO NOT start the engine by shorting across the terminals of the starter motor. This operation will place your life in danger. Only start the engine when you are sitting in the driving seat.

3559 559 M1

3647 157 M1

3559 555 M1

3648 152 M1

SYMBOL

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REF.

CODE

POSITION

DESCRIPTION

3647 643 M1

Near handbrake lever.

DANGER: Danger of being crushed. When stopping the tractor, always apply the parking handbrake before getting off.

3647 299 M1

On the right rear mudguard, with electronic power lift only.

DANGER: Danger of collisions and severe accidents. Stand by the side of a tractor when using the external power lift controls. DO NOT STAND between the tractor and the tool: you could be hit.

3559 553 M1

On the inside of the rear mudguard.

DANGER: Danger of entanglement. Keep well away from spinning shafts. Take care NOT to remain caught up by the PTO driveline. Keep all the guards mounted on the transmission shafts of the tractor or implements.

3647 463 M1

On the left rear mudguard, with electronic power lift only.

DANGER: Danger of collisions and severe accidents. Stand by the side of a tractor when using the external power lift controls. DO NOT STAND between the tractor and the tool: you could be hit.

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SYMBOL

100-13

SECTION 100 - GENERAL INFORMATION

REF.

CODE

POSITION

DESCRIPTION

SYMBOL

Inside cab on top for tractors without second pas3647 032 M1 senger seat and for tractors with frame on left mudguard

WARNING: Danger of being crushed. DO NOT allow anyone to sit on the mudguards or on any other part of the tractor or towed implements.

Tractors with seat belts. On the pillar inside the cab or on the left 3648 447 M1 mudguard for tractors with safety frame.

WARNING: Danger of being crushed. Always wear the seat belt when the safety frame is in the vertical position.

Inside the cab on top or on the left mudguard for 3559 557 M1 tractors with safety frame.

DANGER: The tractor could overturn and crush your chest. Hold firmly on to the steering wheel if the tractor is overturning. DO NOT leave your seat or jump off the tractor.

Inside the cab on top or on the left mudguard for 3559 558 M1 tractors with safety frame.

WARNING: Pay attention. Consult the operation and maintenance manual for information about safety and how to use the tractor.

100-14

P/N 3681774M1

Edition 01-2006

SECTION 100 - GENERAL INFORMATION

REF.

CODE

POSITION

DESCRIPTION

On engine cooling 3559 554 M1 circuit expansion vessel.

DANGER: Jets of hot steam or hot water. Protect the face. The radiator will be under pressure when the engine is hot. Remove the plug with caution when the engine is cold.

3647 275 M1

On both sides of the radiator or intake manifold.

WARNING: Very hot surfaces. The hands and fingers could be scorched. Keep away from hot parts. Observe a safety distance. Keep protections fitted when the engine is running.

3664 188 M1

Position near the front power lift (where fitted).

DANGER: Beware of lifted loads. Keep at a safe distance to prevent being hit or crushed.

3647 158 M1

Positioned near the battery support.

WARNING: Danger of electric shock. Always disconnect the negative battery terminal before removing the battery or before servicing the electrical system.

P/N 3681774M1

Edition 01-2006

SYMBOL

100-15

SECTION 100 - GENERAL INFORMATION

SEALING AND FIXING SEALANTS Apply the sealants given in the table to the surfaces to couple. Prepare the surfaces in the following way before applying the sealants: - remove any deposits with a metal brush; - thoroughly degrease the surfaces with one of the following detergents: trichloroethylene, wash oil or water and soda.

Weak locking and adjuster screws.

Medium-strong thread locking

Loctite 242

Medium-strong locking and threaded parts in general.

Strong thread locking

Loctite 270

Highly resistant fixing, locking and sealing of stud bolts, nuts, screws.

Penetrating thread locking

Loctite 290

Capillary locking and sealing of already mounted parts. Microporosity sealing.

Locker

Loctite 601

Highly resistant fixing of coupling surfaces.

Fixer

Loctite 641

Medium-strong resistance fixing of bushes, bearings, etc. Demounting possible using normal tools.

Super-locker

Loctite 638

Highly resistant fast fixing of cylindrical parts. Dynamic work.

High-temperature locker

Loctite 648

Fast fixing of cylindrical parts highly resistant to heat.

Hydraulic-hermetic

Loctite 542

Sealing of threaded unions on hydraulic or pneumatic pipes up to Âž" in diameter

Pipe-hermetic

Loctite 572

Sealing of threaded unions in general.

Thick flat-hermetic

Loctite 510

Sealing of flat surfaces. Manual application.

Flat-hermetic

Loctite 573

Sealing of precise flat surfaces. Applied by hand or by screen-print systems.

Smooth couplings

Threaded couplings locking and sealing

Loctite 222

Hydraulic fittings

USE

Weak locking

Engine

100-16

TYPE

Sealing of surfaces

DENOMINATION

Hermetic plastic - spray type Hermetic - paste type

Perkins Hylomar power part

sealing

screws,

sealing

Sealing of cylinder head surfaces. Sealing of sump, cover surfaces.

P/N 3681774M1

Edition 01-2006

SECTION 100 - GENERAL INFORMATION

LUBRICANTS AND FUELS

Engine with filter

7.5

Specifications

Ambient temperature

AGROLUBE



LOWER THAN 0 °C



API CE/SG CCMC D4 MB 227.0

FROM 0 °C TO 27 °C



HIGHER THAN 27 °C

KRONOS 30

API CE/CF-4/SG ACEA E2-B2-A2 MB 228.1

ALL TEMPERATURES

KRONOS 15W40

2440

2435

2430

Assembly to be filled

Quantity dm3 (litres)

7.5

Synch reverse shuttle gearbox, steering and hydraulic circuit (1)

API GL 4 MF 1135

ALL TEMPERATURES

SINCROS/B

Powershuttle gearbox, steering and hydraulic circuit (2)

MF CSMMF 1135-1141

ALL TEMPERATURES

SINCROS/C

Rear final drives (each)

API GL 5 MIL-2105 D

ALL TEMPERATURES

KRIPTOS 80W-90

Front axle differential box

3.5

5.0

API GL 4 MF 1135

ALL TEMPERATURES

SINCROS/B

Front final drives (each)

1.5

API GL 5 MIL-2105 D

ALL TEMPERATURES

KRIPTOS 80W-90

Braking circuit

0.9



ALL TEMPERATURES

XERONS RED (3)

Greasing points



ALL TEMPERATURES

G.M.P. GREASE EP

Cooling circuit

Fuel tank

AGROLUBE MANTOS antifreeze in the following proportions according to temperature: Ambient temperature Degrees °C -8° -15° -25° -35° Antifreeze percentage % 20 30 40 50

Decanted and filtered diesel fuel

ISO 8217 DMA, SB2869 A1 or A2 (cetane N.: 45 min)

(1) Use LANDINI M2 C 86 C, M-F 1135 compliant oils. LANDINI specifications require use of additives and anti-noise properties. The use of different types of oil, or mixing other types of oil into the oil supplied with the tractor can lead to increased noise. (2) Powershuttle transmission with electrohydraulic reverse shuttle uses ONLY AGROLUBE SINCROS / C oil. (3) LANDINI S/ENG/I 102 compliant brake circuit mineral based oil.

P/N 3681774M1

Edition 01-2006

100-17

SECTION 100 - GENERAL INFORMATION

CONVENTIONAL UNITS OF MEASUREMENT Units of measurement (international system) Force in (Newtons)

Conversion:

1N 1 kg

= 0.1019 kg = 9.81 N

Power in kW (kilowatts)

Conversion:

1 1 1 1 1 1

= = = = = =

Torque in Nm (Newton meter)

Conversion:

1 Nm 1 kgm 1 kgm

kW kW CV HP HP HP

= 0.1019 kgm = 9.81 Nm = 10 Nm *

Specific consumption in g/kWh Conversion: (grams per kilowatt-hour)

1 g/kWh = 0.736 g/HPh 1 g/HPh = 1.36 g/kWh

Pressure in kPa (kilopascal)

1 1 1 1 1 1 1 1 1 1 1 1 1 1

Conversion:

Other units: HP (Horsepower) HP (Horsepower)

1.36 HP 1.34 HP 0.736 kW 0.986 HP 0.746 kW 1.014 HP

kg/cm2 = kg/cm2 = kg/cm2 = kg/cm2 = kg/cm2 = bar = bar = bar = psi = psi = psi = kPa = kPa = kPa =

Other units: g/CVh (grams per horsepower hour)

1 Atm 98.1 kPa 0.981 bar 1 bar * 14.22 psi 100 kPa 1.02 kg/cm2 14.51 psi 6.9 kPa 0.069 bar 0.0703 kg/cm2 0.145 psi 0.0102 kg/cm2 0.01 bar

Other units: kg/cm2 (kilogram/square centimetre) Atm (Technical atmosphere) psi (Pounds per square inch)

* For the sake of simplicity, the Nm and bar units are converted according to ratios 10:1 and 1:1. Conversion values for Imperial measurement system 0.1 mm

= 3.937 mils

1 mm

= 0.039 inch

= 3.281 ft

1 km

= 0.621 miles

1 cm3

= 0.061 cu.in

= 1.759 pts (0.88 imp. qts)

1 bar

= 14.5038 psi

= 0.035 oz. (0.564 dr)

1 kg

= 2.205 lbs

= 1.102 short ton (0.9842 long ton)

0째 C

= 32째 F

(In the case of temperature differences 1 째C = 1.8 째F)

100-18

P/N 3681774M1

Edition 01-2006

SECTION 100 - GENERAL INFORMATION

STANDARD DRIVING TORQUE VALUES Screws with metric threads Maximum driving torque values for metric threads in kgm. Diameter x pitch dxp (mm)

Class 8.8 screw

Class 10.9 screw

Class 12.9 screw

Normal

Galvanized

Cadmium plated

Normal

Galvanized

Cadmium plated

Normal

Galvanized

Cadmium plated

3x5

0.153

0.137

0.122

0.193

0.173

0.15

0.234

0.21

0.187

4x0.7

0.316

0.284

0.252

0.438

0.394

0.35

0.53

0.477

0.424

5x0.8

0.612

0.55

0.49

0.87

0.78

0.69

1.03

0.93

0.82

6x1

1.06

0.95

0.85

1.48

1.33

1.18

1.78

1.60

1.42

8x1.25

2.51

2.25

2.00

3.54

3.18

2.83

4.24

3.02

3.39

8x1

2.65

2.38

2.12

3.73

3.35

2.98

4.47

4.03

3.57

10x1.5

5.11

4.60

4.08

7.19

6.47

5.75

8.63

7.76

6.90

10x1.25

5.34

4.81

4.27

7.51

6.75

6.00

9.02

8.11

7.21

12x1.75

8.65

7.78

6.02

12.14

10.92

9.71

14.59

13.13

11.67

12x1.25

9.24

8.32

7.39

12.95

11.66

10.36

15.61

14.05

12.48

14x2

13.77

12.39

11.01

19.38

17.44

15.50

23.26

20.93

18.60

14x1.5

14.59

13.13

11.67

20.61

18.55

16.48

24.69

22.20

19.75

16x2

20.91

18.82

16.72

29.38

26.44

23.50

35.30

31.77

28.24

16x1.5

21.83

19.65

17.46

30.81

27.73

24.64

36.93

33.24

29.54

18x2.5

28.87

25.98

23.09

40.61

36.55

32.48

48.77

43.69

39.00

18x1.5

31.42

28.28

25.13

44.28

39.85

35.42

53.06

47.75

42.44

20x2.5

40.81

36.73

32.64

57.34

51.61

45.87

68.77

61.89

56.00

20x2.5

40.81

36.73

32.64

57.34

51.61

45.87

68.77

61.89

56.00

20x1.5

43.97

39.58

35.17

61.93

55.74

49.54

74.28

66.25

59.42

22x2.5

54.23

48.85

43.42

76.32

68.69

61.05

91.53

82.37

73.22

22x1.5

58.26

54.43

46.60

81.93

73.74

65.54

98.36

88.53

78.68

24x3

70.51

63.45

56.40

99.08

89.17

79.26

119.33

107.44

95.50

24x2

74.53

67.13

59.67

105.10

94.59

84.08

125.51

112.95

100.40

27x3

100.36

92.75

82.44

144.89

130.40

115.91

173.46

156.12

138.76

27x2

109.18

98.26

87.34

153.06

137.75

122.44

183.67

165.30

140.97

30x3.5

130.79

125.81

111.03

198.93

177.24

157.54

235.71

212.14

183.60

30x2

151.02

135.91

120.81

212.24

191.02

169.79

254.08

228.67

203.26

P/N 3681774M1

Edition 01-2006

100-19

SECTION 100 - GENERAL INFORMATION Nuts with metric threads Maximum driving torque values for metric threads in kgm. Diameter x pitch dxp (mm)

MAT. 8G

Diameter x pitch dxp (mm)

MAT. 5S

MAT. 8G

MAT. 5S

MAT. 8G

MAT. 5S

MAT. 8G

5x0.8

0.55

0.35

18x2.5

27.00

39.00

17.00

24.50

6x1

0.95

1.30

0.60

0.80

18x1.5

30.50

42.50

19.00

26.50

8x1.25

2.30

3.20

1.40

2.00

20x2.5

30.50

54.00

19.00

34.00

8x1

2.50

3.50

1.60

2.20

20x1.5

42.50

60.00

26.00

37.50

10x1.5

4.60

6.40

2.90

4.00

22x2.5

51.00

72.00

32.00

45.00

10x1.25

4.90

6.80

3.10

4.20

22x1.5

57.00

80.00

36.00

50.00

12x1.75

8.00

11.00

5.00

6.90

24x3

66.00

93.00

41.00

58.00

12x1.25

8.80

12.50

5.50

7.80

24x2

72.00

100.00

45.00

63.00

14x2

12.50

18.00

7.80

11.00

77x3

98.00

140.00

61.00

88.00

14x1.5

14.00

19.50

8.80

12.00

27x3

105.00

150.00

66.00

94.00

16x2

19.50

27.50

12.00

17.00

30x3.5

135.00

185.00

85.00

116.00

16x1.5

21.00

29.50

13.00

18.50

30x2

145.00

205.00

91.00

128.00

100-20

Standard nuts galvanised

Lowered nuts galvanised

Standard nuts galvanised

Lowered nuts galvanised

P/N 3681774M1

Edition 01-2006

SECTION 200 ENGINE

SECTION 200 - ENGINE TABLE OF CONTENTS Description

Page

GENERAL FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-3 ENGINE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-8 SECTIONS . . . . . . . Injection pump Injector . . . . . Turbocharger .

.. .. .. ..

. . . .

.. .. .. ..

. . . .

.. .. .. ..

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

200-10 200-10 200-11 200-11

DIAGRAMS AND CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine fuel feed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine intake and exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

200-12 200-12 200-13 200-14 200-15

ENGINE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-16 COMPRESSION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24 Compression degree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24 Measuring procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-24 ADJUSTMENTS AND TESTS . . . . . . . Valve play adjustment . . . . . . . How to check the belt tension . Injection pressure test . . . . . . Jet inspection . . . . . . . . . . . . .

. . . . .

.. .. .. .. ..

. . . . .

.. .. .. .. ..

. . . . .

.. .. .. .. ..

. . . . .

.. .. .. .. ..

. . . . .

.. .. .. .. ..

. . . . .

.. .. .. .. ..

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

.. .. .. .. ..

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

.. .. .. .. ..

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

200-26 200-26 200-26 200-27 200-28

INJECTION PUMP TUNING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200-29

200-2

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

GENERAL FEATURES GENERAL FEATURES

MF 2430

Engine -

Version/Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

804C-33T

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERKINS

Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diesel, four-stroke

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

turbocharger

Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

direct

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 in line

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

120

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3)

3331

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2

Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19:1

Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW)

69/51

Maximum power rate . . . . . . . . . . . . . . . . . . . . . . . . . . (rpm)

2500

Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm)

217

Maximum torque rate . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM)

1600

Idling rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM)

1000

Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anticlockwise (viewed from flywheel)

Recommended diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

ISO 8217 DMA, BS 2869 A1 or A2 (cetane N.: 45 min)

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forced lubrication with trochoid pump

Capacity of lubricating oil reservoir. . . . . . . . . . . . . . . . (litres)

Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . .

See section 100

Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant/Radiator

Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . (litres)

5.5

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 vane fan

Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centrifugal mechanical type (all speeds)

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical

P/N 3681774M1

Edition 01-2006

200-3

SECTION 200 - ENGINE

GENERAL FEATURES

MF 2435

Engine -

Version/Position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

804C-33T

Manufacturer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERKINS

Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diesel, four-stroke

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

turbocharger

Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

direct

Number of cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 in line

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

120

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3)

3331

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2

Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19:1

Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW)

75/56

Maximum power rate . . . . . . . . . . . . . . . . . . . . . . . . . . (rpm)

2500

Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm)

236

Maximum torque rate. . . . . . . . . . . . . . . . . . . . . . . . . . (RPM)

1600

Idling rate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (RPM)

1000

Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anticlockwise (viewed from flywheel)

Recommended diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

ISO 8217 DMA, BS 2869 A1 or A2 (cetane N.: 45 min)

Lubrication system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forced lubrication with trochoid pump

Capacity of lubricating oil reservoir . . . . . . . . . . . . . . . . (litres)

Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . .

See section 100

Cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant/Radiator

Capacity of cooling fluid reservoir . . . . . . . . . . . . . . . . . (litres)

5.5

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 vane fan

Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centrifugal mechanical type (all speeds)

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical

200-4

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

GENERAL FEATURES

MF 2440

Engine -

Version/Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

804C-33T

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PERKINS

Cycle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diesel, four-stroke

Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

turbocharger

Injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

direct

Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 in line

Bore . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

Stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

120

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . (cm3)

3331

Firing order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2

Compression ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19:1

Power ISO 3046/1 . . . . . . . . . . . . . . . . . . . . . . . . . . (HP/KW)

81.5/60

Maximum power rate . . . . . . . . . . . . . . . . . . . . . . . . . . (rpm)

2500

Maximum torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Nm)

251

Maximum torque rate . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM)

1600

Idling rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(RPM)

1000

Rotation direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Anticlockwise (viewed from flywheel)

Recommended diesel fuel . . . . . . . . . . . . . . . . . . . . . . . . . . .

ISO 8217 DMA, BS 2869 A1 or A2 (cetane N.: 45 min)

Lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Forced lubrication with trochoid pump

Capacity of lubricating oil reservoir. . . . . . . . . . . . . . . . (litres)

Recommended lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . .

See section 100

Cooling system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Coolant/Radiator

Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . (litres)

5.5

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7 vane fan

Regulator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Centrifugal mechanical type (all speeds)

Ignition system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical

P/N 3681774M1

Edition 01-2006

200-5

SECTION 200 - ENGINE

GENERAL FEATURES

MF 2430

MF 2435

MF 2440

LS Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With overhead valves controlled by tappets

Suction valves -

number per cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

Exhaust valves: -

number per cylinder. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

Gap between valves and tappets with engine cold: -

intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

0.15-0.25

exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (mm)

0.15-0.25

For further technical data about the timing system . . . . . . . . . . . . Fuel system Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Turbocharged

Air cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dry filter with two elements removable for maintenance

Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perkins

Fuel cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Paper filter on injection pump delivery

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cam driven

Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Perkins

Speed governor, at all rates, built into the pump. . . . . . . . . . . . . .

Perkins

Automatic variable advance, built into the pump. . . . . . . . . . . . . .

Perkins

Cold starting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Thermostarter

For further technical data about the fuel system -

Fixed advance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5Â°

Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-3-4-2

Injectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -

Pressure setting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (bar)

200-6

Perkins 181 - 191

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE (Continued)

GENERAL FEATURES

MF 2430

MF 2435

MF 2440

Lubrication Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

forced, by means of pump

Oil cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gauze filter (on pump intake) cartridge filter (on engine delivery)

Oil pressure at 1500 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . (bar)

3รท5

Recommended oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See section 100

Cooling Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

water, with forced circulation by centrifugal pump operated by the gears of the timing system

Capacity of cooling fluid reservoir. . . . . . . . . . . . . . . . . . . . . . . (l)

5.5

Cooling fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

vane fan

Fan diameter and number of blades . . . . . . . . . . . . . . . . . . . (mm)

Recommended fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See section 100

P/N 3681774M1

Edition 01-2006

200-7

SECTION 200 - ENGINE

ENGINE VIEWS

5LA0333

1 Engine view left side 1. 2. 3. 4. 5. 6. 7. 8. 9.

200-8

Injector Glow plug Intake manifold Breather Exhaust cap Flywheel guard Flywheel Oil dipstick Oil filter

10. Oil regulating valve 11. Oil drain cap 12. Oil sump 13. Pressure sensor 14. Injection pump 15. Oil filler cap 16. Fan 17. Coolant pump

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

5LA0334

2 Engine view right side 1. 2. 3. 4. 5. 6.

Valve cover Thermostat Alternator Poly-V belt Pulley Starter motor

P/N 3681774M1

Edition 01-2006

7. 8. 9. 10. 11. 12.

Turbocharger lubrication tube Turbocharger lubrication exhaust tube Exhaust manifold Shutdown valve Turbocharger Upper oil filler cap

200-9

SECTION 200 - ENGINE

SECTIONS Injection pump

5LA0336

3 1. 2. 3. 4. 5. 6.

Control lever Centrifuge masses Adjustment screws Control shaft Adjuster lever Stop solenoid

1. 2. 3. 4. 5. 6. 7.

Propeller shaft Gear Sleeve Stop solenoid Delivery valve Spring Cam

7. Upper body 8. Sleeve 9. Pumping piston 10. Cam 11. Spring 12. Delivery valve

5LA0337

200-10

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE Injector 1. 2. 3. 4. 5. 6.

Fuel delivery Fuel return Injector body Pressure spring Sealing needle Nozzle

5LA0338

5 Turbocharger 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Intake manifold Compressor body Compressor impeller Bearing Lubrication oil inlet Bearing Turbine body Turbine impeller Exhaust manifold Lubrication oil drain Exhaust gas inlet 5LA0342

P/N 3681774M1

Edition 01-2006

200-11

SECTION 200 - ENGINE

DIAGRAMS AND CIRCUITS Engine lubrication

5LA0339

7 Engine lubrication circuit diagram 1. 2. 3. 4. 5. 6. 7.

200-12

Piston lubrication pipe Rocker arm Camshaft Main delivery pipe Oil radiator Intermediate wheel Adjustment valve

8. Crankshaft 9. Oil pump 10. Oil filter 11. Oil sump 12. Exhaust valve 13. Turbocharger lubrication pipe 14. Turbocharger

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE Engine fuel feed

5LA0335

8 Engine fuel feed diagram 1. 2. 3. 4.

Injectors High pressure pipe Return line Injection pump

P/N 3681774M1

Edition 01-2006

5. 6. 7. 8.

Fuel delivery pipe Return pipe to tank Fuel filter Fuel tank

200-13

SECTION 200 - ENGINE Engine cooling

5LA0340

9 Engine cooling circuit diagram 1. 2. 3. 4.

200-14

Radiator Thermostat Head Bypass

5. Coolant pump 6. Coolant pipes 7. Oil radiator

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE Engine intake and exhaust

5LA0341

10 Engine intake and exhaust diagram 1. Turbocharger 2. Exhaust gas

P/N 3681774M1

Edition 01-2006

3. Intake

200-15

SECTION 200 - ENGINE

ENGINE TROUBLESHOOTING Faults The engine fails to start

Possible causes 1. Battery slightly low.

Check, recharge the battery and replace it if necessary.

2. Connections to battery terminals corroded or slack.

Clean, inspect, tighten the nuts and, if necessary, replace any excessively corroded terminals and nuts.

3. Circuit open.

Close the circuit.

4. Intake/exhaust incorrect.

200-16

Remedies

valve

play

Adjust valve play.

5. Intake/exhaust valve seized.

Replace.

6. Piston rings seized or broken.

Replace piston ring.

7. Cylinder and piston rings worn.

Lap and use larger size parts.

8. Big end pins and bearings seized.

Repair or replace.

9. Foreign body in combustion chamber.

Demount and repair the chamber. Remove the foreign body.

10. Intake/exhaust incorrect.

timing

Adjust the valve play and check the timing of the intake/exhaust valves.

11. Incorrect timing of injection pump on engine.

Correctly time the injection pump on engine.

12. Impurities or water accumulated in the fuel pipes.

Detach the pipes, the injection pump and thoroughly clean them. If necessary, clean and dry the fuel tank.

13. No fuel in tank

Fill tank.

14. No fuel supplied to injection pump

Check and, if necessary, replace the fuel pump.

15. Air in the fuel circuit.

Check the pipes, unions, fuel pump, filters and injection pump for air. Lastly, bleed the circuit.

16. Starter motor damaged.

Repair or replace the starter motor.

17. Faulty thermostarter.

Check or replace the thermostarter.

valve

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

Faults

Possible causes

The engine starts but then stops

The engine overheats.

Remedies

1. Idling rate too low.

Adjust idling rate.

2. Irregular fuel supply to injection pump

Check the flow rates on the test bench.

3. Impurities or water accumulated in the fuel pipes.

Detach the pipes, the injection pump and thoroughly clean them. If necessary, clean and dry the fuel tank.

4. Fuel filters clogged

Replace integral filter cartridges.

5. Abnormal play between valves and rocker arms.

Adjust play between valves and rocker arms.

6. Valves seized, burnt or cracked.

Replace the valves.

7. Air in the fuel circuit.

Check the pipes, unions, fuel pump, filters and injection pump for air. Lastly, bleed the circuit.

8. Injection pump controls damaged.

Replace the damaged parts.

9. Damaged cylinder head seal.

Replace the seal.

10. Piston ring seized or broken.

Replace piston ring.

11. Cylinder and piston rings worn.

Lap and use larger size parts.

12. Big end seized.

Repair or replace.

and

bearings

13. Incorrect alignment of piston ring gap.

Correct gap alignment.

1. Centrifugal pump of engine cooling circuit inefficient.

Overhaul the pump and replace it if necessary.

2. Thermostat inefficient.

Replace the thermostat.

3. Radiator partially inefficient.

Remove any scaling by washing. Check and repair any leaks from the tubes.

4. Scaling in the places where coolant passes in the cylinder head and crankcase.

Thoroughly wash.

5. The belt that controls the centrifugal pump and fan is too slack.

Check and adjust the belt tension.

6. Cooling fluid (quantity insufficient).

Top up the level in the expansion tank using the recommended fluid. (Continued)

P/N 3681774M1

Edition 01-2006

200-17

SECTION 200 - ENGINE

Faults

Possible causes

Remedies

7. Incorrect engine timing.

Check and engine.

correctly

time

the

8. Injection pump with incorrect setting.

Adjust the injection pump on the test bench in compliance with the setting table.

9. Air filter clogged.

Clean the unit and replace the filter element if necessary.

10. Cylinder liners cracked

Replace.

11. Damaged cylinder head seal.

Replace the seal.

12. Spring rings jammed or damaged.

Replace the spring rings.

Coolant temperature too low.

1. The radiatorâ&#x20AC;&#x2122;s cooling capacity is excessive owing to incorrect operation of the thermostat.

Replace the thermostat.

Low engine power and irregular operation.

1. Incorrect timing of injection pump on engine.

Correctly time the injection pump on engine.

2. Damaged automatic variable advance in injection pump.

Overhaul the injection pump and adjust it on the test bench in compliance with the setting table.

3. Worn timing system pin.

Overhaul the injection pump and adjust it on the test bench in compliance with the setting table.

4. Irregular fuel supply to injection pump

Overhaul the injection pump and adjust it on the test bench in compliance with the setting table.

5. Speed governor, at all rates, damaged.

Overhaul the injection pump and adjust it on the test bench in compliance with the setting table.

6. Injectors partially clogged or damaged.

Clean, overhaul and correctly calibrate the injectors.

7. Impurities or water accumulated in the fuel pipes.

Detach the pipes, the injection pump and thoroughly clean them. If necessary, clean and dry the fuel tank.

8. Fuel pump damaged.

Replace fuel pump.

9. Air filter clogged.

Clean the unit and replace the filter element if necessary.

10. Length of rod between accelerator and injection pump badly regulated.

Adjust rod length.

(Continued)

200-18

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

Faults

Possible causes

Abnormal knocking in engine.

Remedies

11. Injection pump with maximum screw badly adjusted.

Adjust the maximum screw.

12. Drop in engine compression due to: - jammed spring rings; - worn cylinder liners; - worn or badly adjusted valves.

Replace the damaged parts or overhaul the engine if necessary.

13. Big end bearing and main bearing worn.

Measure or replace.

14. Reduced cooling effect from radiator.

Defective thermostat (check/ replace). Adjust fan belt tension.

15. Insufficient cooling fluid.

Check to make sure that no water leaks from the cooling system and clean it.

16. Wrong fan belt tension.

Adjust fan belt tension.

17. Thermostat worn.

Check/replace.

1. Injectors partially clogged or damaged.

Clean, overhaul and correctly calibrate the injectors.

2. Impurities in the fuel pipes.

Clean the pipes and replace any that are excessively dented. Clean the injection pump if necessary.

3. Incorrect timing of injection pump on engine.

Correctly time the injection pump on engine.

4. The engine shaft knocks owing to excessive play on one or more main or big end bearings, or too much play in the supports.

Grind the drive shaft pins; fit larger bearings and bearing rings.

5. Drive shaft unbalanced.

Check shaft alignment and balancing. Replace the shaft if necessary.

6. Flywheel fixing bolts slackened.

Replace the slackened bolts and tighten all bolts to the prescribed torque value.

7. Axes of connecting rods not parallel.

Straighten the connecting rods, check the parallelism of the axes and, if necessary, replace the connecting rods themselves.

8. Piston knocking due to abnormal wear.

Ream the cylinder liners and fit larger pistons. (Continued)

P/N 3681774M1

Edition 01-2006

200-19

SECTION 200 - ENGINE

Faults

Abnormal smoke from the engine: black or dark grey smoke.

Grey smoke tending towards a whitish, grey-blue or blue colour.

Possible causes

Remedies

9. Noisy piston pins owing to excessive play in the piston bosses and big end pin. Bushes free in the big end housing.

Fit a larger piston pin, true the piston bosses and big end bushes. Replace the bushes.

10. Ticking due to noisy timing system.

Make sure that there are no broken springs, that the play between stems and guides, tappets and housings is not excessive. Adjust the play between the valves and rocker arms.

1. Maximum flow rate of injection pump too high.

Adjust the injection pump on the test bench in compliance with the setting table.

2. The injection pump is delayed too much or the automatic variable advance is damaged.

Correctly time the injection pump on the engine or check the automatic variable advance.

3. Too much advance.

pump

Correctly time the injection pump on engine.

4. Injectors partially and/or totally clogged or with incorrect setting.

Clean, overhaul and correctly calibrate the injectors; replace them if necessary.

5. Air filter clogged.

Clean the unit and replace the filter element if necessary.

6. Drop in engine compression due to: - jammed spring rings; - worn cylinder liners; - worn or badly adjusted valves.

Replace the damaged parts or overhaul the engine if necessary.

7. Injection pipes damaged.

Check the condition of the pipes and replace them if necessary.

8. Diesel fuel with the wrong specifications.

Use suitable diesel fuel.

9. Engine used at high temperatures and altitudes.

Use a higher powered engine.

10. Exhaust pipe clogged.

Clean pipe.

1. The injection pump is delayed too much or the automatic variable advance is damaged.

Correctly time the injection pump on the engine or check the automatic variable advance.

2. Injectors clogged or defective.

Clean, overhaul and correctly calibrate the injectors; replace them if necessary.

3. Oil oozes from the piston rings owing to jammed rings or worn liners.

Replace the damaged parts or overhaul the engine if necessary.

injection

(Continued)

200-20

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

Faults

Possible causes 4. Too much advance.

The engine fails to stop.

Oscillation, instability in the rotation rate. - when idling

- when operating

injection

Remedies pump

Correctly time the injection pump on engine.

5. Oil oozes through the intake valve guide owing to worn valve stems or guides.

Overhaul the cylinder head.

6. The engine fails to reach operating temperature (thermostat damaged).

Replace the thermostat.

7. Spring rings incorrectly mounted/positioned.

Mount correctly.

8. Intake/exhaust incorrect.

Adjust valve play and timing.

valve

timing

9. Diesel fuel with the wrong specifications.

Use suitable diesel fuel.

10. Water in the fuelling circuit.

Check and repair.

1. Stopping electromagnet damaged.

Replace the electromagnet.

2. Speed governor, at all rates, damaged.

Overhaul the injection pump and adjust it on the test bench in compliance with the setting table.

1. Piston rings seized or broken.

Replace the spring rings.

2. Big end pins and bearings seized.

Repair or replace.

3. Big end bearings and main bearings worn.

Measure or replace.

4. Injection pump regulator damaged.

Repair or replace.

5. Water in the fuelling circuit.

Clean and repair.

1. Intake/exhaust valves seized.

Replace.

2. Big end pins and bearings seized.

Repair or replace.

3. Big end bearings and main bearings worn.

Measure or replace.

4. Injection pump regulator damaged.

Repair or replace.

5. Water in the fuelling circuit.

Clean and repair. (Continued)

P/N 3681774M1

Edition 01-2006

200-21

SECTION 200 - ENGINE

Faults

Possible causes

Excessive vibration in engine.

Excessive fuel consumption.

Excessive consumption lubricating oil.

Water in the lubricating oil.

Fuel in the lubricating oil.

Remedies

1. Intake/exhaust valves jammed.

Replace.

2. Spring rings jammed or damaged.

Replace.

3. Big end jammed.

Repair or replace.

and

bearings

4. Big end bearings and main bearings worn.

Measure or replace.

5. Big end fixing bolts slackened.

Tighten to the prescribed torque value.

6. Injection pump regulator damaged.

Repair or replace.

7. Too much advance.

pump

Check and adjust.

1. Loss of compression from valve housing.

Lap valve housing.

2. Radiator cools too much.

Thermostat defective.

3. Excessive delay on injection pump

Check and adjust.

1. Piston rings seized or broken.

Replace.

2. Cylinder and piston rings worn.

Lap and use larger size parts.

3. Incorrect alignment of piston ring gap.

Correct gap alignment.

4. Inverted assembly of piston rings

Mount correctly.

5. Impurities in combustion chamber.

Demount and remove the impurities.

6. Intake/exhaust worn.

Measure or replace.

injection

valve

guide

7. Lubricating oil with wrong specifications.

Use suitable lubricating oil.

8. Leaks from lubricating oil pipes.

Repair/replace.

1. Damaged cylinder head housing seal.

Replace.

2. Cylinder liners cracked

Replace.

1. Intake/exhaust valves seized.

Replace.

2. Piston rings seized or broken.

Replace.

3. Cylinder and piston rings worn.

Lap and use larger size parts. (Continued)

200-22

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

Faults

Possible causes

Lubricating oil pressure too low.

1. Big end bearings and main bearings worn.

Measure/replace.

2. Big end bolts slackened.

Tighten bolt.

3. Cylinder liner cracked

Replace.

4. Lubricating oil with wrong specifications.

Use suitable lubricating oil.

5. Leaks from lubricating circuit pipes.

Repair/replace.

6. Lubricating oil filter clogged.

Replace.

7. Worn valve.

Clean, adjust or replace.

pressure

Remedies

monitoring

8. Insufficient oil capacity. Temperature exhaust.

increase

1. Intake/exhaust incorrect.

valve

Top up to maximum oil level. play

Adjust valve play.

2. Loss of compression from valve housings.

Lap valve housing.

3. Spring rings seized or broken.

Replace piston ring.

4. Reduced cooling effect from radiator.

Check/replace thermostat. Check/adjust fan belt slip.

5. Insufficient cooling fluid.

Check for leaks from the system/ repair.

6. Fan belt tension incorrect.

Adjust tension. (Continued)

P/N 3681774M1

Edition 01-2006

200-23

SECTION 200 - ENGINE

COMPRESSION TEST If the engine performances are insufficient, check the compression value of each cylinder besides the injection apparatus (overhaul the atomizers and injection pump).

WARNING

Do not use matches, cigarette lighters or torches as a light source on the machine since it contains inflammable fluids.

Compression degree The compression degree is a value that indicates the quantity of air taken in and the condition of the retaining parts of the cylinder (spring rings and valves). The compression value in the cylinders ensures that the cylinders themselves operate correctly in the condition where the same amount of fuel is injected per cylinder per phase. Insufficient compression not only lowers the engine performance but also prevents the fuel from burning completely as there is not enough air to achieve a perfect combustion. In this case, the engine will no longer operate efficiently and will consume too much fuel. This leads to smoke at the exhaust and a reduction in the exhaust orifices. Since the compression degree also depends on the engine temperature (there are lower compression values with a cold engine, higher ones with a hot engine), the compression value must only be measured when the engine has reached its operating temperature. Measuring procedure 1. Bring the engine to operating temperature. 2. Turn off the engine. 3. Turn the regulator knob to the STOP position to prevent fuel from flowing to the injectors. 4. Remove the injector that corresponds to the cylinder being examined. 5. Allow the internal combustion engine to turn over a few times by means of the starter motor in order to expel any carbon residues. 6. Mount the dummy injector in place of the one demounted previously, fitting a copper washer in between.

200-24

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE 7. Connect the compression tester with an adapter and pressure gauge (1) to the tested cylinder and take the measurements by allowing the internal combustion engine to run by means of the starter motor until the pressure gauge reading becomes stable.

5LA0348

11 8. Test the compression in the remaining cylinders by repeating the previously described operations 4-5-6-7. Compare the measured values with the ones in the table below: Compression pressure at 250 RPM. (kg/cm2) Normal

Limit

Difference in the compression pressure off the various cylinders (kg/cm2)

MF 2430

29 ± 1

24.5 ± 1

2−3

MF 2435

29 ± 1

24.5 ± 1

2−3

MF 2440

29 ± 1

24.5 ± 1

2−3

Model

Also consider that every 100 metres above sea level corresponds to a decrease of approximately 1%. Although the aim is to always obtain the highest compression values, the important thing is to make sure that the compression in the cylinders is uniform as this allows the engine to operate in a regular way. It is advisable to check a second time if considerable drops in the compression in a cylinder are noted. Before measuring, pour normal engine oil (about a spoonful) through the injector hole, into the cylinder. Allow the engine to run so that the oil spreads over the walls of the cylinder, then repeat the test and compare the two test values obtained. If higher values are recorded during the second test, this means that the piston rings could be worn and/or the cylinder liners could be ovalized or damaged. If the values are not higher than the previous ones, the fault will be due to the valves. Only a slight improvement in the compression will indicate that both the valves and piston rings are in order. Whatever the case, also consult "Troubleshooting" on page 16.

P/N 3681774M1

Edition 01-2006

200-25

SECTION 200 - ENGINE

ADJUSTMENTS AND TESTS Valve play adjustment 1. Check the valve play when the engine is cold. 2. Move the piston to top dead centre (TDC) in the cylinder where the measurements are being taken. 3. Using a spanner (2), slacken off the lock nut and then the adjuster screw, using a screwdriver (1). Make sure that the valve cap is correctly positioned and free from dirt deposits.

5LA0343

12 4. Insert a thickness gauge (3, Fig. 12) with a clearance (G) of: 0.15 â&#x2C6;&#x2019; 0.25 mm between the rocker arm and cap of the intake/ exhaust valve. Tighten the adjuster screw (1) until the rocker arm pad touches the thickness gauge and fix with the lock nut (2).

2LA0060

13 How to check the belt tension 1. Press with your hand in the direction of the arrow the middle of the belt (1) between the alternator (2) and the coolant pump (3). If the deflection (F) is: F = 5 â&#x2C6;&#x2019; 10 mm the belt tension is correct. 2. If the deflection does not correspond to specifications, adjust the tension by changing the position of the alternator (2). Loosen the screw (4) and move the alternator and fasten it appropriately. Repeat the test as shown in step 1. Tighten screws (4) and (5) if it is successful.

200-26

5LA0350

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE Injection pressure test Carefully remove the carbon deposits from the injector before proceeding with the inspections. 1. Connect the injector (1) to the high pressure hose of the injector test instrument (2). 2. Slowly operate the lever of the instrument (2) and note down the value indicated by the pressure gauge when the injector (1) starts to spray. The correct injection pressure should be: 181 - 191 bars

2LA0064

3. If the measured pressure is lower than specified, remove and carefully clean each component of the injector. Repeat the test.

P/N 3681774M1

Edition 01-2006

200-27

SECTION 200 - ENGINE Jet inspection Operate the lever (3) of the injector test instrument (2) four − six times, depending on the prescribed injection pressure. Check the jets at the same time. - Check that the jet is neither continuous nor fragmented. - Make sure that the jet of fuel around the median line of the injector is tapered in shape and that the delivery angle is about 150°.

2LA0066

Refer to the figure on the right in order to define the shape of the jet: • normal jet: see fig. 17; • anomalous jet: see fig. 18. Place a sheet of white paper 30 cm under the atomizer and make sure that the jet forms a perfect circle. After injection, make sure that no fuel drips from the injector. Make sure that there are no fuel leaks from the injection hole if the pressure is slightly lower than the prescribed value.

2LA0067

2LA0068

200-28

P/N 3681774M1

Edition 01-2006

SECTION 200 - ENGINE

INJECTION PUMP TUNING 1. Turn the crankshaft so that the suction valve of cylinder 4 is open and the exhaust valve is nearly closed. 2. Check reference alignment as shown in the figure.

5LA0345

19 3. With the pump fitted and the fastening screws loose, remove the closing cap (1) on the pump cover.

5LA0346

20 4. Fit a dial gauge as shown in the figure. Turn the flywheel back slowly to take the piston to BDC at beginning of delivery (the dial gauge will stop descending).

5LA0349

P/N 3681774M1

Edition 01-2006

200-29

SECTION 200 - ENGINE 5. Reset the dial gauge and turn the flywheel slowly to take the reference index to position as shown in the figure.

5LA0347

22 6. Check on the dial gauge that the stroke of the cylinder piston is 0.5 mm. 7. Otherwise, turn the pump to obtain the required stroke. When these conditions occur, fasten the pump and tighten the respective fastening screws.

5LA0344

200-30

P/N 3681774M1

Edition 01-2006

SECTION 300 CLUTCH

SECTION 300 - CLUTCH TABLE OF CONTENTS Description

Page

GENERAL SPECIFICATIONS OF THE LX (OX) 12” CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-3 GENERAL SPECIFICATIONS OF THE HI-LO SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-3 DESCRIPTION AND OPERATION OF THE CLUTCH AND HI-LO SYSTEM . . . . . . . . . . . . . . . . . . . . . . 300-4 Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-4 HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-6 SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-7 CLUTCH HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-10 CLUTCH ASSEMBLY TROUBLESHOOTING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-11

CLUTCH REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-12 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-13 CLUTCH HOUSING - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-14 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 300-17 CLUTCH HOUSING WITH HI-LO - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reverse shuttle float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

300-2

P/N 3681774M1

300-19 300-19 300-24 300-29

Edition 01-2006

SECTION 300 - CLUTCH

GENERAL SPECIFICATIONS OF THE LX (OX) 12â&#x20AC;? CLUTCH Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

single plate, dry

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, pedal operated

Engaging and disengaging mechanism . . . . . . . . . . . . . . . . . . . . . . .

diaphragm spring

Type of coating on the clutch driven plate . . . . . . . . . . . . . . . . . . . .

cerametallic

GENERAL SPECIFICATIONS OF THE HI-LO SYSTEM HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

speed reducer

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

planetary gear reduction set with wet multiple plate hydraulic clutch

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

electrohydraulic, operated by button on gear lever

P/N 3681774M1

Edition 01-2006

300-3

SECTION 300 - CLUTCH

DESCRIPTION AND OPERATION OF THE CLUTCH AND HI-LO SYSTEM Clutch The clutch assembly transmits motion from the engine to the driveline. It is engaged and released by means of the control pedal arranged on the left of the steering wheel on the cab floor. A dry single plate clutch is fitted. Motion is transmitted by the engine to the gearbox when the pressure plate,

loaded by the diagram spring, presses the friction plate against the flywheel. The friction plate is released when the clutch pedal is pressed and the motion is interrupted.

The HI-LO assembly transmits the motion from the clutch to the driveline. Two ratios can be selected: slow or fast. A planetary reducer gear is found inside the unit for reducing the ratio by 20% and doubling the number for each gear shift. The unit is operated by means of a button on the gear lever which controls the pressurised oil opening and closing solenoid valve inside the pipe (13). To engage high ratios press the button controlling the solenoid valve which sends oil at 17 bars to the piston chambers (3 and 12). The piston (12) operated in this way makes the clutch plates and intermediate plates integral (6) forming a single body with the disc holder hub (7) fitted on the input shaft (14). The piston (3) acts on the thrust plate (4) overcoming the bias of the Belleville spring (5) and releasing the plate (2) which prevents the rotation of the cover (1) on which it is fitted.

In such conditions, the input shaft (14) transmits motion to the hub (7), to the plates and the intermediate plates (6), to the cover (1) and to the whole planetary gear set. The difference between the number of teeth of the double satellites (8) and the planetary gears (10 and 11) causes a mechanical block which forces the output shaft (9) to turn with the whole assembly and the input shaft (14) at a 1:1 (or high) ratio. To engage low ratio, press the button controlling the solenoid valve again which sends oil at 17 bars to the piston chambers (3 and 12). The clutch plates (6) are released and the plate (2) is blocked by the biased of the Belleville spring (5) on the pressure plate (4). The cover ring (1) allows the motion from the input shaft (14) to be transferred from the planetary gear set (11) to the output shaft (10) via the satellites (8), thus causing a 20% reduction of the output shaft turns (9).

HI-LO

STANDARD TRANSMISSION

ENGINE

CLUTCH

= 100 % ENGINE RPM

POWERFIVE (HI-LO) TRANSMISSION 100 % ENGINE RPM ENGINE

CLUTCH

POWERFIVE (HI-LO)

= 80 % ENGINE RPM

5LA0183

300-4

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH

3 1

5LA0184

3 2

10 2

HI-LO longitudinal section

P/N 3681774M1

Edition 01-2006

300-5

SECTION 300 - CLUTCH

CONTROLS

5LA0182

3 Clutch and HI-LO controls 1. Clutch control pedal

300-6

2. HI-LO control button

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH

SECTIONS

3 4 5

Ã¸ 304,8 (12")

7 8

9 10 5LA0172

4 Clutch longitudinal section 1. 2. 3. 4. 5.

Flywheel Fixing screw Friction plate Pressure plate Clutch cover

P/N 3681774M1

Edition 01-2006

6. 7. 8. 9.

Diaphragm spring Hub Flexible coupling springs Centring pin

300-7

SECTION 300 - CLUTCH

5LA0159

5 Clutch housing longitudinal section 1. 2. 3. 4. 5. 6. 7. 8.

300-8

Clutch housing Friction plate Pressure plate Clutch cover Flexible coupling springs Diaphragm spring Clutch control collar Clutch fork fastening screw

9. Clutch fork control shaft 10. Clutch control fork 11. Secondary shaft lubrication tube 12. Clutch collar support 13. Input shaft 14. Thrust bearing 15. Flywheel

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 1

12 13 14 15 16

17 18 19 20 21

5 4 3

2 1

24 25 26 27 36

5LA0126

35 34 33 32

31 30 29

HI-LO clutch housing longitudinal section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18.

PTO shaft Input shaft Flexible coupling springs Thrust bearing Flywheel Clutch housing Friction plate Pressure plate Diaphragm spring Clutch cover Clutch control collar Clutch collar support Clutch control fork Single plate clutch piston Pressure plate Spring flange Belleville spring Clutch plates

P/N 3681774M1

Edition 01-2006

19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36.

28 6

Plate holder hub Double satellite Satellite holder housing Satellite pin Output shaft Secondary shaft lubrication tube Output planetary Input planetary Multiple plate clutch piston DT upper shaft Clutch plate DT upper shaft gear DT lower shaft gear Multiple plate clutch cover Oil pipe HI-LO cover Supporting flange DT lower shaft

300-9

SECTION 300 - CLUTCH

CLUTCH HOUSING SEALANT APPLICATION DIAGRAM

4LA0163

7 The types of sealant to apply are indicated in section 100.

300-10

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH

CLUTCH ASSEMBLY TROUBLESHOOTING Faults The clutch slips

The clutch jerks.

The clutch fails to disengage and slips.

Clutch noisy when engaged and/or disengaged.

Clutch pedal too hard to operate.

P/N 3681774M1

Edition 01-2006

Possible causes

Remedies

1. Pressure plate and flywheel wear.

Compare with the values given in the indicated pages. Replace excessively worn parts and adjust the levers and clutch controls.

2. Stretched or damaged diagram spring

Replace the diagram spring.

3. Oil or grease on plate friction material.

Replace the plate. Eliminate the cause that led to the presence of lubricant in the clutch housing and thoroughly clean the friction surfaces.

1. External controls hardened.

Check the hinging and lubricate.

2. Deformed clutch plate.

Replace the plate and adjust the clutch lever.

3. Oil or grease on plate friction surfaces.

Replace the plate. Eliminate the cause that led to the presence of lubricant in the clutch housing and thoroughly clean the friction surfaces.

1. Deformed clutch plate.

Replace the plate.

2. External controls seized.

Check, replace the faulty parts and lubricate.

3. Badly adjusted controls.

Adjust the controls.

1. Worn thrust bearings.

Replace the bearing.

2. Clutch plate with damaged flexible coupling springs.

Replace the plate.

1. External controls hardened.

Check the hinging and lubricate.

2. Hardened pedal hinging.

Check the hinging and lubricate.

300-11

SECTION 300 - CLUTCH

CLUTCH REMOVAL-REFITTING Removal WARNING

Lift and handle all heavy parts with lifting equipment of an adequate capacity. Make sure that the units or parts are supported by appropriately sized harness and hooks. Make sure that there are no bystanders near the load being lifted.

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

WARNING

Proceed as follows: 1. Remove the engine. (See section 200).

5LA0166

8 2. Loosen the screws (1) fastening the clutch to the flywheel (2). Remove the complete clutch assembly.

5LA0185

300-12

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH Refitting WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Refit the clutch housing bearing the following recommendations in mind: -

For orientation of parts, refer to the illustration on page 7

Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all damaged or worn components.

Check the flywheel surface and grind it if needed. Remove no more than 1 mm of material.

Arrange the clutch assembly using tool (1) 02 FRI GL to centre it on the flywheel (2). Fit the clutch cover (3) with diagram spring (4) and tighten the screws.

5LA0167

P/N 3681774M1

Edition 01-2006

300-13

SECTION 300 - CLUTCH

CLUTCH HOUSING - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

1. Remove the engine. (See section 200). 2. Loosen the fastening screw (1), remove the shaft (2) and the clutch fork (3). Remove the collar (4) and thrust bearing (5). Remove the PTO shaft (6).

5LA0087

11 3. Remove the clutch housing from the gearbox housing (see section 400). 4. Remove the lubrication tube (1) of the gearbox primary and secondary shaft.

5LA0168

300-14

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 5. Remove the support (1) from the clutch collar and cover the o-ring (2).

5LA0169

13 6. Remove the snap ring (1) that holds the input shaft (2).

5LA0170

14 7. Remove from the front of the clutch housing the input shaft (1) with reverse shuttle (2).

5LA0171

15 8. Remove the snap rings (2) and (3) from the input shaft (1).

5LA0186

P/N 3681774M1

Edition 01-2006

300-15

SECTION 300 - CLUTCH 9. Remove the synchroniser unit (1) from the reverse shuttle and the gear (2).

5LA0173

10. Remove from the inner part of the input shaft (1) the snap ring (2), the o-ring (3) and the roller bearing (4).

5LA0187

5LA0174

300-16

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH Assembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the clutch housing: -

For orientation of parts, refer to the illustration on page 8.

Before remounting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 10.

Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Check synchroniser X height.

X = 1.25 mm (minimum)

5LA0116

P/N 3681774M1

Edition 01-2006

300-17

SECTION 300 - CLUTCH Proceed as follows: 1. Reassemble and refit the input shaft on the clutch housing. 2. Fit the clutch collar support (1) with lubrication hole orientated as shown by the arrow. Tighten the fastening screws at the specified torque of: 19 - 24 Nm

5LA0179

3. Fit the reverse shuttle synchronisation assembly making sure snap rings (1) and (2) are correctly positioned because they are different.

5LA0180

5LA0181

300-18

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 4. Fit the synchroniser ring (1) and calculate the thickness of the shim which limits the reverse shuttle float. (See procedure on page 29).

5LA0188

CLUTCH HOUSING WITH HI-LO - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

1. Remove the engine. (See section 200). 2. Remove the shaft and the clutch fork. Remove the collar and the thrust bearing. Remove the PTO shaft. Loosen the screws (1) fastening the HI-LO assembly (2).

5LA0083

25 3. Remove the HI-LO assembly (4) from the clutch housing (5) keeping the shaft (1) connected to the collar support (2). For this operation, fit tool (3) 137 PNT GL on the shaft (1) making it attach to the collar support (2) and fasten the screw.

4LA0146

1 26

P/N 3681774M1

Edition 01-2006

300-19

SECTION 300 - CLUTCH 4. Remove the clutch housing from the gearbox housing. (See section 400). 5. Fasten the HI-LO assembly on the work bench and remove the satellite holder housing (1) and the output planetary gear (2).

4LA0147

27 6. Remove the complete clutch plate assembly (1).

4LA0148

28 7. Remove the input shaft (1) with the plate holder hub (2).

4LA0149

300-20

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 8. Remove the clutch cover (1).

4LA0150

30 9. Remove the clutch piston (1) from the clutch cover (2).

4LA0151

31 10. Remove the flange (1) and remove the Belleville spring (2).

4LA0152

32 11. Remove the thrust plate (1), clutch single plate (2) and the clutch piston (3).

4LA0153

P/N 3681774M1

Edition 01-2006

300-21

SECTION 300 - CLUTCH 12. Remove the support collar (1) and use a press to remove the support (2) from the HI-LO cover.

4LA0154

34 13. Remove from the inside of the clutch housing, the snap ring (1) from the output shaft (2).

2 5LA0006

35 14. Remove the complete reverse shutter assembly.

5LA0007

36 15. Remove the snap ring (1) holding the synchroniser stop (2).

1 2

5LA0010

300-22

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 16. Remove the synchroniser unit (1) from the reverse shuttle and the gear (2).

5LA0011

38 17. Extract the roller bearing (2) from the output shaft (1).

5LA0013

P/N 3681774M1

Edition 01-2006

300-23

SECTION 300 - CLUTCH Assembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the clutch housing: -

For orientation of parts, refer to the illustration on page 9.

Before remounting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 10.

Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Check synchroniser X height.

X = 1.25 mm (minimum)

5LA0116

300-24

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH Proceed as follows: 1. Reassembly and refit the output shaft (2) from the clutch housing and fasten it with the snap ring (1).

2 5LA0006

2. Fit the reverse shuttle synchronisation assembly making sure snap rings (1) and (2) are correctly positioned because they are different.

5LA0180

5LA0181

P/N 3681774M1

Edition 01-2006

300-25

SECTION 300 - CLUTCH 3. Fit the synchroniser ring (1) and calculate the thickness of the shim which limits the reverse shuttle float (See procedure on page 29).

5LA0188

44 4. Fit on the support (1) of the HI-LO cover the bearing (2) and the o-rings (3) and (4).

1 2

4LA0161

45 Respect the position and dimensions of the o-rings and bearings as shown in the figure. Fit the bearing (2), then the smooth ring (3) and then the corrugated ring (4).

4LA0160

46 5. With the help a press, fit the support (1) on the HI-LO cover (2). Orient the cover support so that the three holes on the same correspond to those of the cover.

4LA0162

300-26

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 6. Fit and fasten the collar support. 7. Position the internal HI-LO components: -

clutch command piston

clutch single plate Check the friction material thickness of the clutch plate.

pressure plate

Belleville spring

Belleville spring flange

clutch cover

clutch piston.

8. Fit the input shaft (1) with the plate holder hub (2).

4LA0149

48 9. Fit the complete clutch plate and input planetary assembly.

5LA0189

P/N 3681774M1

Edition 01-2006

300-27

SECTION 300 - CLUTCH

Check for absence of scratching, signs of heavy overheating and distortion of the steel plates. Check the friction material thickness of the clutch plates.

4LA0157

50 10. Reassemble the satellite holder housing.

4LA0155

51 11. Fit the satellites (1) and insert the pins (2) with the lubrication hole oriented as shown in the figure.

2 1 4LA0158

52 12. Before fitting the last satellite (1), position the output planetary (2) making sure that the reference on the satellite are present and converge towards the centre. After positioning the third satellite, check that all three signs are correctly oriented. Otherwise, repeat the assembly procedure.

120Â°

The timing error of a tooth will cause noisiness of the assembly. Incorrect timing of two teeth, on the other hand, will cause mechanical jamming of the device.

120Â°

2 4LA0159

300-28

P/N 3681774M1

Edition 01-2006

SECTION 300 - CLUTCH 13. Position the satellite holder housing, assemble and fasten the complete HI-LO assembly in the clutch housing. 14. Complete the inner details for operating the clutch. 15. Refit the engine. (See section 200). Reverse shuttle float adjustment WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Make sure that, once mounted, the reverse shuttle has a float of 0.3- 0.6 mm to ensure that it operates correctly.

Proceed as follows:

1. Measure with a thickness micrometer distance A between the synchroniser ring surface (1) and the coupling plane and the clutch housing (2). Take 3 measurements at 120Â° and calculate the arithmetical average of the three readings.

5LA0112

5LA0111

P/N 3681774M1

Edition 01-2006

300-29

SECTION 300 - CLUTCH

2. Measure with a thickness micrometer distance B between the primary shaft plane (1) and the coupling plane and the clutch housing (2). Take 3 measurements at 120Â° and calculate the arithmetical average of the three readings.

5LA0113

5LA0115

57 3. The shim Sp to be arranged between the reverse shuttle synchroniser ring (1) and the gearbox primary shaft (2) is: Sp = B - A - 0.45 where: B = measured dimension A= measured dimension 0.45 = average operating float Round off to the lower figure. The following shims Sp are available as spare parts:

5LA0190

2.25 mm 2.50 mm 2.75 mm 3.00 mm 3.25 mm

300-30

P/N 3681774M1

Edition 01-2006

SECTION 400 SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF THE SPEEDFIVE GEARBOX AND FINAL DRIVE . . . . . . . . . . . . . . . . . . . . 400-3 MAIN SPECIFICATIONS OF REVERSE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-3 MAIN SPECIFICATIONS OF SUPER FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-3 DESCRIPTION AND OPERATION OF THE SPEEDFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4 Gearbox and reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4 Super final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-4 MAIN SPECIFICATIONS OF POWERFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6 MAIN SPECIFICATIONS OF REVERSE SHUTTLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6 MAIN SPECIFICATIONS OF SUPER FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-6 DESCRIPTION AND OPERATION OF THE POWERFIVE GEARBOX . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7 Gearbox and reverse shuttle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7 Super final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-7 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-8 SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-9 PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-10 GEARBOX HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-12 GEARBOX, RANGE REDUCTION AND REVERSE SHUTTLE AND REVERSE SHUTTLE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-13 SUPER FINAL DRIVE TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-13 GEARBOX REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-14 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-18 GEARBOX HOUSING - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Four gear pack float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4th gear synchronisation float adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

400-19 400-19 400-25 400-31 400-33

GEAR LEVER SUPPORT HOUSING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-35 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400-35

400-2

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

MAIN SPECIFICATIONS OF THE SPEEDFIVE GEARBOX AND FINAL DRIVE Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with 5 ratios, infinitely meshed gears and synchronizers for all speeds

Type of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with helical toothing

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cascade type with 3 speed ranges for a total 15 speeds.

Type of gears. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with straight toothing

Gearbox and final drive controls. . . . . . . . . . . . . . . . . . . . . . . . . . . .

independent, with lever installed on the operator’s right

MAIN SPECIFICATIONS OF REVERSE SHUTTLE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical with straight teeth, installed between the main clutch and gearbox.

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of dedicated lever on the left of the steering wheel

MAIN SPECIFICATIONS OF SUPER FINAL DRIVE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cascade with straight teeth, installed between the gearbox and bevel gear pair. Obtains 30 forward and 30 reverse speeds

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of dedicated lever on the operator’s left

P/N 3681774M1

Edition 01-2006

400-3

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

DESCRIPTION AND OPERATION OF THE SPEEDFIVE GEARBOX Gearbox and reverse shuttle The gearbox is equipped with helical toothed infinitely meshed gears controlled by three synchromesh units. It provides 5 speeds. The range reduction unit is the cascade type with infinitely meshed straight toothed gears. The final drive offers three speed ranges: slow, normal and fast. The reverse shuttle is a mechanical device providing 15 forward gears and 15 reverse gears.

The reverse shuttle is controlled by a specific lever arranged on the left of the steering wheel. The reverse shuttle consists of a straight toothed gear. The reverse shuttle is engaged by means of a synchro-mesh. The reverse shuttle is fitted inside the gearbox housing between the clutch and gearbox. The assembly is lubricated by the oil in the gearbox housing.

Super final drive The super final drive is a mechanical device providing 30 forward gears and 30 reverse gears. The super final drive is installed upstream of the gearbox and is controlled by a dedicated lever to

the operatorâ&#x20AC;&#x2122;s left. The super final drive can be used in low and normal ranges only.

STANDARD GEARBOX

15 FORWARD GEARS REVERSE SHUTTLE

5 GEARS TIMES 3 RANGES

= 15 REVERSE GEARS

GEARBOX

REVERSE SHUTTLE +

WITH

5 GEARS TIMES 3

SUPER

FINAL

SUPER FINAL DRIVE

30 FORWARD GEARS

= 30 REVERSE GEARS

5LA0074

1 Speedfive gearbox configuration

400-4

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Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 1

Normal range

Engine rpm

Slow range

Standard gearbox

Fast range

Working speed

Normal range Slow range

Super final drive

Basic gearbox: speed km/h (15 forward gears and 15 reverse gears)

Optional super final drive (10 ultra slow gears) 5LA0077

2 Speedfive basic gearbox with mechanical reverse shuttle 30 AV + 30 RM with 420/70-28 tyres

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Edition 01-2006

400-5

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

MAIN SPECIFICATIONS OF POWERFIVE GEARBOX Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with 5 ratios, infinitely meshed gears and synchronizers for all speeds

Type of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with helical toothing

HI-LO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch fitted in front of gearbox

Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wet multiple plate, electrohydraulic controlled

Final drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cascade type with 3 speed ranges for a total 30 speeds.

Type of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with straight toothing

Gearbox and final drive controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .

independent, with lever and button installed on the operator’s right

MAIN SPECIFICATIONS OF REVERSE SHUTTLE Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical with straight teeth, installed between the main clutch and gearbox.

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of dedicated lever on the left of the steering wheel

MAIN SPECIFICATIONS OF SUPER FINAL DRIVE Type. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cascade with straight teeth, installed between the gearbox and bevel gear pair. Obtains 60 forward and 60 reverse speeds

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of dedicated lever on the operator’s left

400-6

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

DESCRIPTION AND OPERATION OF THE POWERFIVE GEARBOX Gearbox and reverse shuttle The gearbox is equipped with helical toothed infinitely meshed gears controlled by three synchromesh units. It provides 5 speeds. The Powerfive module is a HI-LO electrohydraulic device consisting of a electro-hydraulically controlled wet multiple plate clutch fitted in front of the gearbox. The Powerfive can engage a 20% step-down for each forward and reverse gear of the gearbox without using the clutch. Engagement is controlled by a solenoid valve operated by the button on the gear lever. The range reduction unit is the cascade type with infinitely meshed straight toothed gears.

The final drive offers three speed ranges: slow, normal and fast. The reverse shuttle is a mechanical device providing 30 forward gears and 30 reverse gears. The reverse shuttle is controlled by a specific lever arranged on the left of the steering wheel. The reverse shuttle consists of a straight toothed gear. The reverse shuttle is engaged by means of a synchro-mesh. The reverse shuttle is fitted inside the gearbox housing between the HI-LO and gearbox. The assembly is lubricated by the oil in the gearbox housing.

Super final drive The super final drive is a mechanical device providing 60 forward gears and 60 reverse gears. The super final drive is installed prior to the gearbox and is controlled by a dedicated lever to the

operatorâ&#x20AC;&#x2122;s left. The super final drive can be used in low and normal ranges only.

STANDARD GEARBOX

30 FORWARD GEARS POWERFIVE HI-LO

+ REVERSE SHUTTLE +

5 GEARS TIMES 3 RANGES

= 30 REVERSE GEARS

GEARBOX

POWERFIVE + HI-LO

REVERSE

WITH

5 GEARS TIMES 3

SUPER

FINAL

SUPER FINAL DRIVE

60 FORWARD GEARS

= 60 REVERSE GEARS

5LA0075

3 Powerfive gearbox configuration

P/N 3681774M1

Edition 01-2006

400-7

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

CONTROLS 1

2 1

5LA0076

4 Gearbox controls 1. Reverse shuttle lever 2. Gear lever 3. Powerfive engagement button

400-8

4. Range selection lever 5. Super final drive lever

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

SECTIONS 1

10 11 12 13 14 15 16 17 18 19

5LA00xx

Gearbox longitudinal section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16.

Reverse shuttle gear Reverse shuttle synchroniser assembly Adjuster shim Primary shaft Snap ring Ball bearing 1st gear 1st and 2nd gear synchronisation assembly 2nd gear Bushing 3rd gear 3rd and 4th gear synchronisation assembly Snap ring Adjuster shim 4th gear Ball bearing

P/N 3681774M1

Edition 01-2006

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Adjuster ring Super final drive micro switch Upper shaft Super final drive micro switch Super final drive micro switch Super final drive double gear Roller bearing 3rd and 4th double gear Secondary shaft 1rd and 2th double gear DT propeller shaft Roller bearing Stop plate

30. 5th gear 31. 32. 33.

5th gear synchroniser Ring nut Lubrication pipe

400-9

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

PERSPECTIVE VIEWS 1

5LA0076

Reverse shuttle unit

Super final drive micro switch

Primary shaft

Secondary shaft

1st and 2nd gear assembly

DT propeller shaft

3rd and 4th gear assembly

5th gear assembly

Super final drive micro switch

Lubrication pipe

6 Gearbox perspective view

400-10

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 1

5LA0078

7 Gearbox lever and fork perspective view 1. Reverse shuttle fork 2. Gear lever 3. Super final drive fork

P/N 3681774M1

Edition 01-2006

4. 3rd and 4th gear fork 5. 1st and 2rd gear fork 6. 5th gear fork

400-11

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

GEARBOX HOUSING SEALANT APPLICATION DIAGRAM

5LA0079

8 The types of sealant to apply are indicated in section 100.

400-12

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

GEARBOX, RANGE REDUCTION AND REVERSE SHUTTLE AND REVERSE SHUTTLE TROUBLESHOOTING Faults

Possible causes

The gearbox, final drive or reverse shuttle disengage spontaneously.

1. Transmission rods and levers incorrectly adjusted.

Adjust correctly.

2. Faulty control rod retention springs.

Replace the springs.

3. Faulty synchro-mesh engaging teeth or engaging sleeves.

Remove the gearbox-transmission housing and replace the synchromesh units or engaging sleeves.

4. Incomplete engagement travel.

Eliminate the causes and adjust for complete travel.

1. Transmission rods and levers incorrectly adjusted.

Adjust correctly.

2. Transmission rods and levers hardened and/or seized.

Check the hinging and lubricate.

3. The central clutch drags.

See sect. 300.

4. Faulty synchro-mesh units or engaging sleeves.

Remove the gearbox-transmission housing and replace the synchromesh units or engaging sleeves.

5. The internal controls do not slide smoothly: rods, forks and sleeves.

Overhaul the controls.

1. Some internal component is worn or defective.

Remove the gearbox-transmission housing and replace the faulty parts.

The gearbox, final drive or reverse shuttle are difficult to engage.

The gearbox, final drive or reverse shuttle operate in a noisy way.

Remedies

SUPER FINAL DRIVE TROUBLESHOOTING Faults Spontaneous engagement.

Possible causes

super

final

drive

Difficult super final drive engagement.

Super final drive noise.

P/N 3681774M1

Edition 01-2006

Remedies

1. External rods and levers incorrectly adjusted.

Adjust correctly.

2. Incomplete engagement travel.

Eliminate the causes and adjust for complete travel.

1. External rods and levers incorrectly adjusted.

Adjust correctly.

2. External rods and levers hardened and/or seized.

Check the hinging and lubricate.

3. The central clutch drags.

See sect. 300.

4. The internal controls do not slide smoothly: rods, forks and sleeves.

Overhaul the controls.

1. Some internal component is worn or defective.

Remove the gearbox housing and replace the faulty parts.

400-13

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

GEARBOX REMOVAL-REFITTING Removal DANGER

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Remove the cab (see section 1100). 2. Remove the engine (see section 200). 3. Loosen the filler caps and drain the gearbox oil. Old oil must be disposed of in compliance with the current laws. 4. Remove all plastic clips fastening the gearbox wiring harnesses. 5. Disconnect from the solenoid valve unit (1), the hydraulic circuit relief pipes and the electrical circuit wiring harnesses.

5LA0081

9 6. Disconnect the gearbox lubrication contoured tube. 7. Disconnect the oil return pipe from the radiator to the solenoid valve block.

400-14

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 8. Disconnect the electrical connector (1) on the reverse safety switch.

5LA0082

10 9. Disconnect the rubber joint sleeve (1) from the two hydraulic circuit suction half tubes.

5LA0080

1 11

10. Disconnect the high pressure hydraulic circuit delivery pipe (1).

5LA0088

1 12

11. Fasten the front axle with two wooden wedges to prevent the engine rocking. 12. Appropriately support the engine, the transmission and the gearbox. Loosen the screws fastening the clutch housing to the engine and separate the two assemblies being careful to maintain the alignment and parallelism of the junction planes. 13. Hitch the clutch housing using appropriate lifting equipment and maintain alignment.

P/N 3681774M1

Edition 01-2006

400-15

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 14. Remove the upper gearbox housing cover.

5LA0084

13 15. Remove the reverse shuttle engagement levers (1) and (2).

5LA0085

14 16. Take out the rod (1) and recover the reverse shuttle fork (2).

5LA0086

15 17. SPEEDFIVE GEARBOX - Loosen the fastening screw (1), remove the shaft (2) and the clutch fork (3). - Remove the collar (4) and thrust bearing (5). - Remove the PTO shaft (6).

5LA0087

400-16

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 17. POWERFIVE GEARBOX - Remove the shaft and the clutch fork. - Remove the collar and the thrust bearing. - Remove the PTO shaft. - Loosen the screws (1) fastening the HI-LO assembly (2).

5LA0083

17 - Remove the HI-LO assembly (4) from the clutch housing (5) keeping the shaft (1) connected to the collar support (2). For this operation, fit tool (3) 137 PNT GL on the shaft (1) making it attach to the collar support (2) and fasten the screw.

4LA0146

1 18

18. Remove the clutch housing (1) from the gearbox housing (2) keeping correct alignment.

5LA0089

19 19. Remove the gearbox housing from the differential housing (see section 500).

P/N 3681774M1

Edition 01-2006

400-17

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX Refitting Comply with the following recommendations when refitting the gearbox housing: WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

- For orientation of parts, refer to the illustration on pages 9, 10 and 11. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 12. - Refit the differential housing (see section 500). - Refit the clutch housing favouring the transmission shaft coupling. Tighten the fastening screws at the specified torque of: 98 - 120 Nm - Powerfive gearbox Fit the HI-LO assembly inside the clutch housing. - Position and fit the PTO shaft, the collar and thrust bearing, the fork and clutch actuating shaft. - Fit the reverse shuttle rod and fork. - Fit the reverse shuttle engagement levers. - Fit the gearbox housing cover. - Connect all hydraulic pipes and electrical connections. - Restore lubricant oil levels. - Refit the engine (see section 200). - Refit the cab (see section 1100).

400-18

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

GEARBOX HOUSING - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Fasten the gearbox housing to the working stand.

5LA0095

20 2. Remove the lubrication tube (1) from the primary shaft gears.

5LA0090

21 3. Remove the gear control lever support (1).

5LA0091

P/N 3681774M1

Edition 01-2006

400-19

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 4. Remove the super final drive rod and fork.

5. Remove the super final drive gear (1).

5LA0092

23 6. Remove the support guard (1) with super final drive double gear (2).

5LA0093

24 7. Remove the rod (1), the fork (2) and the engagement block (3) of the 1st and 2nd gear. Remove the same components of the 3rd and 4th gear. Recover the rod springs and balls.

5LA0094

400-20

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

8. Extract the 4th gear (1) and bearing. Use a plastic hammer for assistance.

4LA0168

26 9. Remove the snap ring (1) to extract the bearing (2) from the 4th gear (2).

1 2 3 4LA0169

27 10. Use a specific extractor to remove the bearing.

5LA0000

28 11. Loosen the nut ring (1) and remove the stop plate (2) of the 5th gear synchroniser.

5LA0100

P/N 3681774M1

Edition 01-2006

400-21

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 12. Extract the stop pin (1) from the engagement block (2) of the 5th gear.

1 5LA0003

30 13. Extract the stop pin (1) from the fork (2), remove the rod (3) and recover the spring and the stop ball. 14. Remove the synchroniser and 5th gear, bearings and slewing bearing.

1 3

5LA0002

31 15. Remove the snap ring (1) of the primary shaft. (Also see detail 1 fig. 33).

5LA0001

5LA0097

400-22

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 16. Remove the snap ring (1) of the primary shaft journal bearing. (Also see detail 2 fig. 33). A pair of snub tipped pliers may be used for this operation as shown in figure 35.

5LA0098

5LA0099

35 17. Remove from the front the primary shaft (1) being careful to withhold all the gears and synchroniser assemblies (2) of the four gears.

5LA0101

36 18. Loosen the fastening screws (1) and remove the stop plate (2) of the secondary shaft bearing (3).

1 3

5LA0004

P/N 3681774M1

Edition 01-2006

400-23

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 19. Remove the front part of the secondary shaft (1) with two double gears (2).

5LA0102

38 20. Extract the reverse shuttle double gear (2) shaft (1) with the bearing (3).

1 5LA0096

39 For this operation, fasten the tool (1) 16 CMB GL to the double gear support. The rear bearing must remain inserted in the housing on the gearbox housing.

5LA0103

400-24

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX Assembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the gearbox: - For orientation of parts, refer to the illustration on pages 9, 10 and 11. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 12. - Apply the tightening torques listed on page 100. - Carefully clean all parts and inspect them. - Replace all o-rings. - Replace all damaged or worn components. - Check rolling tracks of all bearings for anomalies while rolling.

- Lubricate with grease the bearing and o-ring seats.

- Check with a jet of air for obstructions of the channels and lubrication oil passage holes. - Check synchroniser X height. X = 1 mm (minimum)

5LA0116

P/N 3681774M1

Edition 01-2006

400-25

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX Proceed as follows: 1. Fit the reverse shuttle double gear (2) shaft (1) with the bearing.

1 5LA0096

42 2. Fit the secondary shaft (1) and the two double gears (2) with respective support tapered bearings.

5LA0102

43 3. Fit and fasten the bearing stop plate (1) of the secondary shaft (2). The secondary shaft tapered bearing preload is determined by blocking the plate.

5LA0104

44 4. To proceed with the assembly operation: a.Calculate thickness of the shim (1) limiting the four gear pack (2) float. (See procedure on page 31). b.Calculate thickness of the shim (3) limiting the 4th gear synchroniser (4) float. (See procedure on page 33).

5LA0117

400-26

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 5. Position the gears and four gear synchronisers (1) and insert the primary shaft from the top (2).

5LA0106

46 6. Fit from the front the snap ring (1) of the primary shaft. (Also see detail 2 in fig. 48).

5LA0098

5LA0097

48 7. Position the shim (1) limiting the four gear pack (2) float. (For selecting the shim, see procedure on page 31)

5LA0119

P/N 3681774M1

Edition 01-2006

400-27

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 8. Fit from the rear the snap ring (1) of the primary shaft. (Also see detail 1 in fig. 48).

5LA0001

50 9. Fit bearing (2) and snap ring (3) on 4 (1).

gear

3 2 1 5LA0114

51 th

10. Assemble 4 gear (1) with shim (2) and synchroniser ring (3). (For selecting the shim, see procedure on page 33)

5LA00

52 11. Position the 4

gear (1) complete.

5LA0168

400-28

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 12. Fit the super final drive assembly. 13. Fit the following in the order given on the secondary shaft: a. slewing bearing (1) b. bushing (2) c. thrust bearing (3) d. slewing bearing (4) e. 5th gear (5) f. thrust bearing (6) g. synchroniser assembly (7) h. stop plate (8) i. nut ring (9).

5LA0118

Tighten the nut ring at the specified torque of 150 - 170 Nm. 14. Fit the 5th gear rod, the fork and pawl. 15. Fit all internal components for engaging the four gears. Pay attention to the pawl (1) between the rods (2) and (3).

5LA0120

55 16. Fit the balls, the springs and the rod stop caps. 17. Fit the support guard with super final drive double gear. Tighten the screws at the specified torque of: 45 - 52 Nm 18. Position the two screws fastening the gearbox to the clutch housing. Respect the given assembly sequence otherwise it will be impossible to position the screws after fitting the super final drive gear.

19. Fit the super final drive gear.

P/N 3681774M1

Edition 01-2006

400-29

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 20. Fit the rod, the fork and all the super final drive engagement components.

5LA0121

56 After assembly, check that the gear and super final drive engage smoothly without slipping. Otherwise, replace the rods and forks.

400-30

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX Four gear pack float adjustment

Proceed as follows: 1. Pre-fit the gears and 4 gear synchronisation assemblies on the primary shaft. 2. Fit on the primary shaft the snap ring (1) without the shim (2).

5LA0124

5LA0105

58 3. Measure the space L between the snap ring (1) and the hub (2) of the 3rd and 4th gear synchroniser with a dial gauge.

5LA0125

P/N 3681774M1

Edition 01-2006

400-31

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 4. The shim Sp1 to be arranged between the synchroniser and snap ring results from: Sp1 = L - 0.1 where L = measured dimension 0.1 = operating float Round off to the lower figure. The following shims Sp 1 are available as spare parts: 2.985 mm 3.100 mm 3.200 mm 3.250 mm 3.300 mm 3.400 mm 3.500 mm 3.550 mm

400-32

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 4th gear synchronisation float adjustment WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Make sure that the 4th gear synchroniser once fitted has a float of 0.35 - 0.45 mm to ensure that it operates correctly.

Proceed as follows: 1. Measure with a micrometer dimension C between the surface A of the gearbox and the surface B on the 4th gear synchroniser.

5LA0108

60 2. Measure with a micrometric thickness gauge the distance D from the 4a gear.

5LA0109

P/N 3681774M1

Edition 01-2006

400-33

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX 3. The shim Sp2 to be arranged between the synchroniser ring (1) and the 4th gear (2) is: Sp2 = C - D - 0.45 where C = measured dimension D = measured dimension 0.45 = operating float Round off to the lower figure. The following shims Sp 2 are available as spare parts: 1.75 mm 2.00 mm 2.25 mm 2.50 mm 2.75 mm 3.00 mm 3.25 mm

400-34

5LA0122

P/N 3681774M1

Edition 01-2006

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

GEAR LEVER SUPPORT HOUSING Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Remove the cover (1). 2. Remove the cover (2). 3. Loosen the screw (3). 4. Remove the fork (4). 5. Remove the snap ring (5) holding the support (6). 6. Remove the snap ring (7), remove the shaft (9) and remove the springs and respective rings and bearing rings from inside the box (10). 5LA0123

P/N 3681774M1

Edition 01-2006

400-35

SECTION 400 - SPEEDFIVE AND POWERFIVE MECHANICAL GEARBOX

400-36

P/N 3681774M1

Edition 01-2006

SECTION 500 REAR AXLE AND SIDE FINAL DRIVES

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF THE STANDARD BEVEL GEAR PAIR AND DIFFERENTIAL . . . . . . . . . . . . 500-3 MAIN SPECIFICATIONS OF STANDARD SIDE FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-3 MAIN SPECIFICATIONS OF GT BEVEL GEAR PAIR AND DIFFERENTIAL . . . . . . . . . . . . . . . . . . . . . . 500-3 MAIN SPECIFICATIONS OF GT SIDE FINAL DRIVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4 BEVEL GEAR PAIR AND DIFFERENTIAL TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4 SIDE FINAL DRIVES TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-5 PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-10 DIFFERENTIAL HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-12 STANDARD SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . 500-13 GT SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . 500-14 REAR DIFFERENTIAL HOUSING REMOVAL-REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-15 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-19 REAR DIFFERENTIAL HOUSING - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential support tapered bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . Pinion and ring teeth clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500-20 500-20 500-28 500-31 500-34 500-35 500-37

STANDARD SIDE FINAL DRIVE - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Axle shaft taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel hub taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500-39 500-39 500-40 500-41 500-43

GS SIDE FINAL DRIVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-45 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 500-46

500-2

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

MAIN SPECIFICATIONS OF THE STANDARD BEVEL GEAR PAIR AND DIFFERENTIAL Bevel gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With helical toothing

Bevel gear pair gear ratio. . . . . . . . . . . . . . . . . . . . . . . . .

9/38

Clearance between bevel pair teeth . . . . . . . . . . . . . . . . .

(mm)

0.18 - 0.34

Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with two satellite gears

Mechanical control of diff lock . . . . . . . . . . . . . . . . . . . . .

Electrohydraulic with mechanical engagement

MAIN SPECIFICATIONS OF STANDARD SIDE FINAL DRIVES Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With straight toothing

Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11/62

MAIN SPECIFICATIONS OF GT BEVEL GEAR PAIR AND DIFFERENTIAL Bevel gear type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With helical toothing

Bevel gear pair gear ratio. . . . . . . . . . . . . . . . . . . . . . . . .

9/41

Clearance between bevel pair teeth . . . . . . . . . . . . . . . . .

(mm)

0.18 - 0.34

Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with two satellite gears

Mechanical control of diff lock . . . . . . . . . . . . . . . . . . . . .

Electrohydraulic with mechanical engagement

MAIN SPECIFICATIONS OF GT SIDE FINAL DRIVES Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

With straight toothing

Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51/10

P/N 3681774M1

Edition 01-2006

500-3

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

DESCRIPTION AND OPERATION The rear transmission transmits drive from the gearbox to the side final drives, by means of the bevel gear pair. The bevel gear pair is the type with helical toothing and is supported by taper roller bearings. The differential has two satellite gears and is provided with a mechanically engaged, electro-hydraulically engaged lock. The side final drives are the type with straight

toothing and are controlled by the bevel gear pair output axle shaft, the same that control the main brakes. 4WD is engaged by the spring-on device which engages automatically also when the engine is stopped. The spring-on coupling is a mechanical, electrically released device.

BEVEL GEAR PAIR AND DIFFERENTIAL TROUBLESHOOTING Faults

Possible causes

Remedies

Noisy transmission when the tractor is on the move, even with the gears in neutral (not due to the side final drives).

1. Satellite and planetary gears incorrectly adjusted or worn.

Detach the rear transmission housing, replace the worn parts and correctly adjust the differential gears.

2. Excessive play in the groove where the axle shafts are shrunk on to the crown wheels.

Remove the rear transmission housing and replace the damaged parts.

Noisy transmission when the tractor is on load and without load.

1. Some internal component is faulty or defective.

Detach the rear transmission housing, replace the worn parts and correctly adjust the differential gear play.

Noisy transmission with overheating.

2. Insufficient coupling play between the pinion teeth and bevel gear pair.

Remove the rear transmission housing and correctly adjust the bearings that support the ring bevel gear.

SIDE FINAL DRIVES TROUBLESHOOTING

500-4

Faults

Possible causes

Remedies

Noisy side final drives when the tractor is on the move, even with the gears in neutral.

1. Some internal component is faulty or defective.

Remove the side final drive housing and replace the damaged parts.

2. Excessive play in the groove where the wheel axle shafts are shrunk on to the side final drives.

Remove the side final drive housing and replace the damaged parts.

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

CONTROLS 1

1 2

5LA0127

1 Rear differential controls 1. Differential lock switch

P/N 3681774M1

Edition 01-2006

2. 4WD selection switch

500-5

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

SECTIONS 1

29 28 27 26 25

24 23

20 19 18 17 16 15 14 13

5LA0126

Rear differential longitudinal section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

500-6

Upper shaft Ball bearing Fast range gear Engagement hub Snap ring Normal range shaft Ball bearing Snap ring PTO shaft sleeve PTO shaft PTO upper shaft PTO hydraulic clutch PTO output shaft PTO gear (1000) PTO gear (540) Proportional PTO gear Proportional PTO shaft Pinion Taper bearing Bushing

21. Ball bearing 22. Thrust bearing washer 23. Reduction gear 24. DT gear 25. DT shaft (rear) 26. Oil duct 27. DT engagement sleeve 28. Spring 29. Plate 30. Snap ring 31. Spacer 32. Snap ring 33. Ball bearing 34. Sleeve 35. DT shaft (front) 36. Fast range gear 37. Ring nut 38. Taper bearing 39. Snap ring 40. Spacer

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 1

5LA0128

Rear differential transversal section 1. 2. 3. 4. 5. 6. 7. 8. 9.

Differential lock rod Spring Differential lock fork Differential lock hydraulic actuator Supporting flange Adjuster shim Axle shaft Taper bearing Slewing bearing

P/N 3681774M1

Edition 01-2006

10. 11. 12. 13. 14. 15. 16. 17. 18.

Planetary gear Satellite gear Satellite pin Slewing bearing Differential housing Taper bearing Axle shaft Adjuster shim Supporting flange

500-7

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 1

5LA0130

Standard side final drive section 1. 2. 3. 4. 5. 6. 7. 8. 9.

500-8

Wheel hub O-ring Wheel hub tapered bearing Drive axle tapered bearing Spacer Reducer cover Drive axle tapered bearing Adjuster shim Retention ring

10. Side final drive body 11. Axle shaft 12. Brake assembly 13. Ring gear 14. Snap ring 15. Adjuster shim 16. Wheel hub tapered bearing 17. Fixing screw 18. Retention ring

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 1

5LA0131

GT side final drive sections 1. 2. 3. 4. 5. 6. 7. 8.

Axle shaft Brake assembly Retention ring Snap ring Radial roller bearing Inner guard External guard fastening screws External guard

P/N 3681774M1

Edition 01-2006

9. 10. 11. 12. 13. 14. 15.

Taper bearing Retention ring Wheel hub Taper bearing Gear Nut Inner guard fastening screws

500-9

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

PERSPECTIVE VIEWS 1

Range selector

Proportional PTO shaft

PTO shaft

DT engagement unit (Spring-on)

Pinion

DT axle

Ring gear

Range assembly

5LA0129

6 Rear transmission assembly perspective view

500-10

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 1

Axle shaft Differential assembly Reduction gear Wheel hub 5LA0133

7 GT side final drive perspective view

P/N 3681774M1

Edition 01-2006

500-11

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

DIFFERENTIAL HOUSING SEALANT APPLICATION DIAGRAM

5LA0132

8 The types of sealant to apply are indicated in section 100.

500-12

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

STANDARD SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM

4LA0166

9 The types of sealant to apply are indicated in section 100.

P/N 3681774M1

Edition 01-2006

500-13

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

GT SIDE FINAL DRIVE HOUSING SEALANT APPLICATION DIAGRAM

4LA0167

10 The types of sealant to apply are indicated in section 100.

500-14

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

REAR DIFFERENTIAL HOUSING REMOVAL-REFITTING Removal DANGER

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Remove the cab (see section 1100). 2. Loosen the filler caps and drain the transmission oil. Old oil must be disposed of in compliance with the current laws. 3. Remove all plastic clips fastening the gearbox wiring harnesses. 4. Disconnect the hydraulic pipes and the power lift electrical connections. 5. Disconnect the rear current socket electrical connection. 6. Disconnect the oil suction tube (1) from the gearbox.

5LA0136

1 11

P/N 3681774M1

Edition 01-2006

500-15

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 7. Disconnect: - the speed sensor electrical connector (1); - the right brake linkage (2); - the spring-on device oil supply tube (3); - the brake cylinder oil supply tube (4); - the differential lock cylinder oil supply tube (5).

5LA0135

12 8. Disconnect the supply tube (1) from the PTO clutch and brake (2).

2 5LA0138

13 9. Disconnect: - the hydraulic tube (1); - the brake cylinder oil supply tube (2); - the left brake linkage (3); - the gearbox oil return tube (4); - the high pressure hydraulic circuit delivery pipe (5).

5LA0134

3 14

10. Remove the upper gearbox cover (1) and the lower differential housing cover (2).

5LA0137

500-16

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 11. Loosen two lower and upper screws between gearbox and differential housing.

5LA0062

16 12. Engage the permanently meshed super final drive gear (1).

5LA0139

17 13. Fasten the front axle with two wooden wedges to prevent the engine rocking. 14. Appropriately support the differential housing and the front transmission. Loosen the external screws fastening and separate the two assemblies being careful to maintain the alignment and parallelism of the junction planes. Remove the PTO shaft from the back of the transmission to facilitate separation of the two assemblies. 15. Standard side final drives - Ensure the side final drives (1) to an appropriate lifting device. - Loosen the fastening screws to the differential housing. - Loosen the differential housing side final drive (2).

4LA0136

P/N 3681774M1

Edition 01-2006

500-17

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 15. GT side final drives - Ensure the external guard (1) of the side final drive to an appropriate lifting device. - Loosen the fastening screws to the inner guard (2). - Remove the outer component of the side final drive.

5LA0060

19 - Ensure the lifting tool (1) 100 RID GL to the inner guard (2). - Loosen the inner and outer screws for fastening the inner components to the differential housing and removing it keeping it well aligned to facilitate sliding of brake discs on the axle shaft.

5LA0059

500-18

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Refitting Comply with the following recommendations when refitting the differential housing: WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

- For orientation of parts, refer to the illustration on pages 6 and 7. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 12. - Refit the differential housing favouring the transmission shaft coupling. Tighten the fastening screws at the specified torque of: 98 - 120 Nm - Fit the differential housing lower cover. - Fit the gearbox upper cover. - Fit the side final drives. - Connect the brake linkages. - Connect the oil supply tubes of the brake cylinders. - Connect the spring-on device oil supply tube. - Connect the differential lock cylinder oil supply tube. - Connect the PTO clutch and brake oil supply tubes. - Connect all hydraulic pipes between differential and gearbox. - Connect all electrical connections. - Restore lubricant oil levels. - Refit the cab (see section 1100).

P/N 3681774M1

Edition 01-2006

500-19

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

REAR DIFFERENTIAL HOUSING - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Fasten the differential housing to the working stand. 2. Remove the spring (1) and the brake external lever (2). Hold the lever (3) pulled and remove the pressure plate (4).

5LA0058

21 3. Remove the range lever support and the hydraulic power lift. 4. Remove the spring pins, remove the rods (1) and recover the engagement blocks (2).

5LA0056

500-20

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 5. Loosen the fixing screws (1) and remove the plate (2).

5LA0055

23 6. With the help of a lever, remove the shaft (1) from the slow /R range.

5LA0053

24 Remember that the double gear (1) is not easy to remove because it is obstructed by the fast range shaft.

5LA0054

25 7. With the help of a lever, move the upper shaft (1) slightly forward to allow access to the snap ring.

5LA0140

P/N 3681774M1

Edition 01-2006

500-21

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 8. Remove the snap ring (1) from its seat.

5LA0052

27 9. Remove the upper shaft (1) and recover the fast range gear (2) and engagement hub (3).

5LA0051

28 10. Recover the slow range/R double gear (1).

5LA0050

29 11. Remove the differential lock actuator (1).

5LA0049

500-22

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

Be careful when removing the differential lock spring. Use protective gloves to hold the spring compressed with your hand.

12. Remove the rod (1) and recover the fork (2) and the spring (3) from inside the differential housing.

5LA00048

31 13. Refit on the PTO clutch cover.

5LA00047

32 14. Remove the clutch assembly (1) and remove the PTO shaft (2).

5LA0046

P/N 3681774M1

Edition 01-2006

500-23

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 15. Remove the snap ring (1) from the normal range shaft (2).

5LA0045

34 16. Remove the normal range shaft (1) from inside the differential housing using the tool (2) 33 DIF GL as shown in the figure.

5LA0044

35 17. Loosen the upper PTO shaft (2) nut ring (1).

5LA0041

36 18. Remove the upper PTO shaft (1).

5LA0040

500-24

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 19. Remove the differential support (2) flange (1). Appropriately mark the left and right flange to reposition it again correctly.

5LA0032

38 20. Remove the complete differential assembly (1).

5LA0031

39 21. Position the differential assembly and disassemble as follows: - remove the spring pin (1) holding the satellite holder pin (2); - remove the body from the differential (3); - extract the two satellites (4) and the respective slewing bearing (5); - extract the two planetary gears (6) and the respective slewing bearings (7).

5LA0027

40 22. Loosen the tapered pinion lock nut.

5LA0030

P/N 3681774M1

Edition 01-2006

500-25

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 23. Remove the tapered bearing (1). Remove the snap ring (2) fitted on the tapered pinion shaft (3).

5LA0029

42 24. Loosen the bevel pinion (1) from the differential housing with the respective gears and spacers.

5LA0141

43 25. Lever inside the differential housing to move the spring-on device forward.

5LA0142

44 26. Remove the complete assembly (1) and recover the DT gear (2) and the slewing bearing (3).

5LA0143

500-26

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

Be very careful when removing the springon device contrast spring because it is highly compressed and withheld in position only by the snap ring. Use appropriate safety devices.

27. Remove the snap ring (1) and remove the spacer (2).

5LA0144

46 28. Fit the assembly on the tool (1) 164 DT GL to compress the spring (2) and remove the snap ring (3).

5LA0145

P/N 3681774M1

Edition 01-2006

500-27

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the differential: - For orientation of parts, refer to the illustration on pages 6 and 7. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 12. - Apply the tightening torques listed on page 100. - Carefully clean all parts and inspect them. - Replace all o-rings. - Replace all damaged or worn components. - Check rolling tracks of all bearings for anomalies while rolling.

- Lubricate with grease the bearing and o-ring seats.

- Check with a jet of air for obstructions of the channels and lubrication oil passage holes. Proceed as follows: 1. Adjust the position of the pinion (1). (See procedure on page 31). 2. Adjust the preload of the two pinion taper bearings (2). (See procedure on page 34). 3. Adjust the preload of the differential support tapered bearings (3). (See procedure on page 35). 4. Adjust pinion and ring (4) teeth clearance. (See procedure on page 37). 5LA0146

500-28

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 5. Reassemble and refit the spring-on unit. Use the tool 164 DT GL already used for disassembly to compress the contrast spring. 6. Fit the bevel pinion and respective gears and bearings. 7. Reassemble the differential assembly fastening inside the body (3) the two satellite gears (6) with the respective slewing bearings (7), the two satellite gears (4) with the respective slewing bearings (5) fastening the pin (2) with a spring pin (1).

5LA0027

49 8. Position the differential assembly inside the housing. 9. Fit the differential support flange and tighten the fastening screws at a specified torque of: 48 - 52 Nm Respect the flange assembly position following the marking made during disassembly.

Make sure that the clearance between the pinion and ring teeth is from 0.18 to 0.30 mm with a maximum admitted variation of 0.1 mm.

5LA0018

50 10. Fasten and block the upper PTO shaft.

P/N 3681774M1

Edition 01-2006

500-29

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 11. Fasten and block the normal range shaft (1) using tool (2) 37 DIF GL.

5LA0017

12. Position the PTO shaft and the clutch assembly. 13. Fit the PTO clutch cover. 14. Fit the differential lock fork (1), the rod (2) and the spring (3). Adjust the screw (4) to centre the fork (1) in the engagement sleeve (5). Check that the engagement pins of the sleeve have a minimum clearance with respect to the planetary gear surface.

5LA0016

15. Fit the differential lock actuator. 16. Position the slow range/R double gear. 17. Fit and fasten the upper shaft with fast speed gear and engagement hub. 18. Fit and fasten the slow range/R shaft. 19. Fit all range engagement internal components. 20. Position and fasten the power lift and range lever support. 21. Fit all brake components.

500-30

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Pinion position adjustment

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. This adjustment procedure is required whenever the rear pinion tapered bearing (1), bevel pair or differential housing is replaced. Make sure that after being fitted the pinion is positioned with respect to the ring at a minimum dimension of B = 120 mm to ensure the correct operation of the bevel pair. Dimension B may vary according to the correction shown on the pinion.

5LA0147

53 Proceed as follows: 1. Fit the rear tapered bearing (1) on the tool (2) 45 DIF GL.

5LA0024

54 2. Measure dimension C with a micrometer thickness gauge. This is the distance between the tapered bearing abutment on the guard and the bevel pinion supporting surface.

5LA0148

P/N 3681774M1

Edition 01-2006

500-31

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 3. Observe the value A printed on the differential housing.

5LA0026

56 4. Observe the value D printed on the bevel pinion.

5LA0025

57 5. The shim Sp to be arranged between outer bearing ring and differential casing abutment is: Sp = A - [(B + D) + C] if D is positive or Sp = A - [(B - D) + C] if D is negative 5LA0149

58 where: A =Value printed on the differential housing B = Nominal dimension C = Measured dimension D = Value printed on the bevel pinion Round off to the lower figure.

500-32

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Example 1: A =133.80 mm. Value printed on the differential housing B = 120 mm. Nominal dimension C = 11.5 mm. Dimension measured D = +0.15 mm. Value printed on the bevel pinion Sp = 133.8 - [(120 + 0.15) + 11.5] = 2.15 mm Round off to the lower figure. Example 2: A =133.3 mm. Value printed on the differential housing B = 120 mm. Nominal dimension C = 11.8 mm. Dimension measured D = -0.12 mm. Value printed on the bevel pinion Sp = 133.3 - [(120 -0.12) +11.8] = 1.62 mm Round off to the lower figure. 6. Insert the calculated shim Sp, fit the tapered bearings, the pinoin and the lock nut.

P/N 3681774M1

Edition 01-2006

500-33

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Pinion taper bearing preload adjustment

Proceed as follows: 1. Preliminarily tighten the bevel pinion lock nut.

5LA0030

59 2. Use a plastic hammer to settle the pinion on the bearings. 3. Tighten the lock nut to obtain a rolling torque of the pinion of 3 - 4 Nm.

5LA0023

60 4. Use a plastic hammer to settle the pinion on the bearings again. 5. Measure the rolling torque again and when the correct value is reached, rivet the edge of the nut into the pinion shaft grooves.

500-34

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Differential support tapered bearing preload adjustment

Proceed as follows: 1. Fit the bevel ring on the differential body and tighten the screws at a specified torque of: 110 - 120 Nm

2. Fit the two dummy bearings (1) 35 DIF GL on the differential body (2).

5LA0022

61 3. Position the differential inside the box blocking it with the supporting flanges. Respect the flange assembly position following the marking made during disassembly.

P/N 3681774M1

Edition 01-2006

500-35

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 4. Using a lever, shift the differential assembly against the support B. Measure with a thickness gauge the space X between the dummy bearing and the abutment on the differential body. Make sure that the dummy bearing is perfectly in contact with the support B. Repeat the measurement three times and calculate the arithmetical average of the three readings.

5LA0021

62 5. The total shim St to be inserted considering the preload of 0.1 mm is: St = X + 0.1 where: X = measured dimension 0.1 = functional preload The total shim St must be split between the left and right supporting flange as shown in the following procedure â&#x20AC;&#x153;Pinion and ring teeth clearance adjustmentâ&#x20AC;?.

500-36

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Pinion and ring teeth clearance adjustment

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. Make sure that the clearance between the pinion and ring teeth is after assembly 0.18 - 0.34 mm to ensure the correct operation of the bevel gear.

Proceed as follows: 1. Position a dial gauge on the differential housing to measure the clearance between the pinion and ring teeth.

5LA0018

63 2. A correct average clearance should be between 0.18 mm and 0.34 mm, thus an average 0.26 mm will be considered for the successive calculations. 3. Make the differential assembly slide between the two supporting flanges until the dial gauge detects a clearance between the teeth of 0.26 mm. Take three measurements at 120Â° and calculate the arithmetical average of the three readings. 4. Measure with a thickness gauge the space X1 between the supporting flange A and the dummy bearing (1). Take three measurements at 120Â° and calculate the arithmetical average of the three readings.

5LA0150

P/N 3681774M1

Edition 01-2006

500-37

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 5. Given the value X1 and the total shim St previously detected (see procedure on page 35), the space X2 between the supporting flange B and the dummy bearing (2) is: X2 = S t - X 1 where: St = measured dimension X1 = measured dimension The values X1and X2 correspond to the shim values Sp1 and Sp2 if the fitted dummy bearings have the same thickness as real tapered bearings to be fitted. Differences will therefore be checked.

6. Measure with a micrometric thickness gauge, the thickness V1 of the real tapered bearing (1) and the thickness Z1 of the dummy bearing (2). Calculate the difference of thickness ∆S1. Repeat the same procedure for the other bearings. ∆S1 = V1 - Z1 ∆S2 = V2 - Z2

5LA0019

65 7. The right Sp1 and left Sp2 shims to be inserted inside the bearings are: Sp1 = X1 ± ∆S1 Sp2 = X2 ± ∆S2 where: X1 = measured dimension ∆S1 = calculated thickness difference X2

= measured dimension

∆S2 = calculated thickness difference Round off to the lower figure within 0.05 mm.

5LA0157

500-38

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Example: St = 3.6 mm. Dimension measured with the procedure “Differential support tapered bearing preload adjustment” X1 = 1.6 mm. Dimension measured ∆S1 = 0.15 mm. Calculated value ∆S2 = -0.10 mm. Calculated value X2

= 3.6 - 1.6 = 2.0 mm

Sp1 = 1.6 + 0.15 = 1.75 mm Sp2 = 2.0 -0.1 = 1.9 mm

STANDARD SIDE FINAL DRIVE - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows with the side final drive removed from the differential housing: 1. Fasten to the wheel hub (1) the lifting tool (2) 131 RID GL. 2. Loosen the fasten screws of the cover (3), remove the entire group including the tapered bearing (4) and the axle shaft (5) from the side final drive body (6).

3 4 5

6 4LA0137

67 3. Remove the snap ring (1). 4. Using a press, remove the wheel hub (2) from the cover (3) recovering the gear (4) and the bearing (5).

3 5

4 4LA0138

P/N 3681774M1

Edition 01-2006

500-39

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the side final drive: - For orientation of parts, refer to the illustration on page 8. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 13. - Apply the tightening torques listed on page 100. - Carefully clean all parts and inspect them. - Replace all o-rings. - Replace all damaged or worn components. - Check rolling tracks of all bearings for anomalies while rolling.

- Lubricate with grease the bearing and o-ring seats.

Proceed as follows: 1. Adjust the preload of the two axle shaft taper bearings (1). (See procedure on page 41). 2. Adjust the preload of the two wheel hub taper bearings (2). (See procedure on page 43).

5LA0151

69 3. Fit the cover assembly and fasten the screws.

500-40

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 4. Fit on the wheel hub (1) the tool (2) 131 RID GL and check that the rolling torque is: 15 - 35 Nm

1 2

4LA0142

70 Axle shaft taper bearing preload adjustment

Proceed as follows: 1. Measure with a micrometer thickness gauge the distance A1 between the reducer resting surface and the axle shaft taper bearing seat.

4LA0139

P/N 3681774M1

Edition 01-2006

500-41

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 2. Measure with a micrometer thickness gauge or dial gauge the distance B1 between the cover resting surface and the axle shaft taper bearing seat.

5LA0153

72 To easily determine the distance B1 make use of the tool (1) 130 RID GL which holds in position the outer ring of the axle shaft tapered bearing.

4LA0140

73 3. The shim S1 to be arranged between the taper bearing outer ring (1) and the resting plane on the side final drive body (2) is:

where:

S1 = (A1 - B1) + P

A1 = measured dimension B1 = measured dimension P = 0.05 mm. Functional preload Round off to the lower figure.

5LA0154

500-42

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Wheel hub taper bearing preload adjustment

Proceed as follows: 1. Measure with a micrometer thickness gauge the distance A2 between the reducer resting surface and the wheel hub taper bearing seat.

5LA0152

75 2. Measure with a micrometer thickness gauge or dial gauge the distance B2 between the cover resting surface and the wheel hub taper bearing seat.

5LA0155

P/N 3681774M1

Edition 01-2006

500-43

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

To easily determine the distance B2 make use of the tool (1) 130 RID GL which holds in position the outer ring of the wheel hub bearing.

4LA0140

77 3. The shim S2 to be arranged between the taper bearing outer ring (1) and the resting plane on the side final drive body (2) is:

where:

S2 = (A2 - B2) + P

A2 = measured dimension B2 = measured dimension P = 0.15 mm. Functional preload Round off to the lower figure.

5LA0156

500-44

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

GS SIDE FINAL DRIVE Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows with the inner and outer side final drives separated and removed from the differential housing: 1. Loosen the lock nut (1) and remove the gear (2). 2. Remove the taper bearing (3) and remove the wheel hub (4) from the outer final drive (5).

5LA0065

79 3. Remove the o-ring (2) from the inner final drive (1). 4. Remove the snap ring (3) from the radial bearing (4) and remove the inner axle shift (5). To remove the radial bearing from its seat, use tool 103 RID GL for 10 teeth axle shafts and tool 104 RID GL for 11 teeth axle shafts.

5LA0066

P/N 3681774M1

Edition 01-2006

500-45

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the side final drive: - For orientation of parts, refer to the illustration on page 9. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 14. - Apply the tightening torques listed on page 100. - Carefully clean all parts and inspect them. - Replace all o-rings. - Replace all damaged or worn components. - Check rolling tracks of all bearings for anomalies while rolling.

- Lubricate with grease the bearing and o-ring seats. Proceed as follows: 1. Insert the wheel hub with the tapered bearing in the outer final drive body. 2. Fit the gear (1) and preliminary fasten the lock nut (2). 3. Tighten the nut to reach a rolling torque of: 6 - 8 Nm

5LA0067

500-46

P/N 3681774M1

Edition 01-2006

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES 4. Fit the radial bearing on the inner axle shaft. To fit the radial bearing in its seat on the axle shaft, use tool 103 RID GL for 10 teeth axle shafts and tool 104 RID GL for 11 teeth axle shafts.

5LA0068

82 5. Insert the o-ring (1), the spacer (2) on the axle shaft (3). 6. Fit the axle shaft and inner final drive. 7. Assemble the inner final drive to the outer final drive.

5LA0069

P/N 3681774M1

Edition 01-2006

500-47

SECTION 500 - REAR AXLE AND SIDE FINAL DRIVES

500-48

P/N 3681774M1

Edition 01-2006

SECTION 510 FRONT AXLE

SECTION 510 - FRONT AXLE TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF FRONT AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3 Axle 710/515 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3 Axle 716/513 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-4 SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-5 DIFFERENTIAL ASSEMBLY - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-10 Pinion position adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-11 Pinion taper bearing preload adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-13 Pinion and crown teeth clearance adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-14 FINAL DRIVE - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-16 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 510-18

510-2

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE

MAIN SPECIFICATIONS OF FRONT AXLE Axle 710/515 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spheroid cast iron construction, pivoting, with central mount

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrolock

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle epicyclical

DT engagement/disengagement . . . . . . . . . . . . . . . . . . .

Mechanical, electro-hydraulically disengaged

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

By switch on the operator's right.

Bevel torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13/51

Bevel pair ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 3.923

Final drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 4.6

Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 18.046

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil bath

Axle 716/513 Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Spheroid cast iron construction, pivoting, with central mount

Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrolock

Final drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle epicyclical

DT engagement/disengagement . . . . . . . . . . . . . . . . . . .

Mechanical, electro-hydraulically disengaged

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

By switch on the operator's right.

Bevel torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13/53

Bevel pair ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 4.076

Final drive ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 4.6

Total ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 18.753

Brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Oil bath

P/N 3681774M1

Edition 01-2006

510-3

SECTION 510 - FRONT AXLE

DESCRIPTION AND OPERATION The front axle for 4WD models consists of a spheroid cast iron central body which incorporates the lockable differential assembly and a final drive. The drive torque is transmitted by the differential to the final drives through the axle shafts, each of which is braked by oil bath wet plates. The axle can swing around horizontally as it is

borne by two supports fixed to the chassis. The spring-on front drive engagement unit is a mechanically engaged and electro-hydraulically released device controlled by a switch arranged on the driver's right. 4WD is always engaged when the tractor stops to ensure perfect braking.

CONTROLS 1

1 2

5LA0127

1 1. Differential lock switch

510-4

2. 4WD selection switch

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE

SECTIONS

5LA0286

Central final drive section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Left axle shaft Screw Brake housing cover Ring nut Piston Brake housing Taper bearing Satellite pin Screw Ring nut Lock housing O-ring O-ring Piston Brake disc Counter disc Hydrolock housing Spring guide O-ring Thrust slewing bearing Right axle shaft Snap ring

P/N 3681774M1

Edition 01-2006

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Slewing bearing O-ring Piston O-ring Union Cap Spring Snap ring Brake hub Bevel pinion ring Bevel pinion O-ring Taper bearing Shim Taper bearing Bevel ring gear Differential mount Snap ring Brake hub Axial guard Planetary gear

510-5

SECTION 510 - FRONT AXLE

5LA0287

3 Final drive section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

510-6

Ring gear Pin stop roller Circlip Screw Ring Hub o-ring Axle shaft o-ring Upper pin cover Fork Tapered bearings for wheel hub Flange

12. Circlip 13. Satellite holder cover 14. Ring nut 15. Planetary gear 16. Circlip 17. Washer 18. Spacer 19. Satellite gear 20. Shimming ring 21. Satellite pin 22. Roller bearing

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE

DIFFERENTIAL ASSEMBLY - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Loosen the differential mount fastening screws, remove the complete assembly (1) using tool (2) 75 DTI GL and bushing 75a DT GL.

5LA0288

4 2. Fasten the vice assembly and remove the differential lock oil supply tube (1).

5LA0289

5 3. Remove the hydrolock housing (1) with the differential lock engagement sleeve (2) and the brake discs (3) from the piston holder housing (4).

5LA0290

P/N 3681774M1

Edition 01-2006

510-7

SECTION 510 - FRONT AXLE 4. Remove the brake housing cover (1) with the brake discs (2-3) from the brake housing (4).

5LA0291

7 5. Using tool 82 DT GL, remove the ring nut (1) and the one of the other mount.

5LA0292

8 6. Remove the two housings (1 and 2) with the differential unit.

5LA0293

9 7. Remove the bevel pinion ring nut (1).

5LA0294

510-8

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE 8. Remove the pinion (1) from the seat with the tapered bearing outer ring (2) and shim (3).

5LA0314

11 9. After removing the screws (1), remove the ring bevel gear (2) and disassemble the differential.

5LA0315

12 10. Extract piston (1) from the housing (2) by introducing air.

5LA0316

P/N 3681774M1

Edition 01-2006

510-9

SECTION 510 - FRONT AXLE Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the front differential: - For orientation of parts, refer to the illustration on page 5. - Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Proceed as follows: 1. Assemble by reversing the remove sequence and adjust as follows: - Adjust the pinion position (1). (See procedure on page 11). -

Adjust the preload of the two pinion taper bearings (2). (See procedure on page 13).

Adjust pinion and ring teeth clearance (3). (See procedure on page 14). 5LA0295

510-10

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE Pinion position adjustment

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. This adjustment procedure is required whenever the rear pinion tapered bearing, bevel pair or differential housing is replaced. Make sure that after being fitted the pinion is positioned with respect to the crown at a minimum dimension of B = 90 mm to ensure the correct operation of the bevel pair. Dimension B may vary according to the correction shown on the pinion.

Proceed as follows: 1. Measure dimension A with a micrometer thickness gauge. This is the distance between the tapered bearing abutment on the differential mount (1) and the bevel pinion supporting surface (2).

5LA0296

15 2. Observe the value D printed on the bevel pinion.

5LA0025

P/N 3681774M1

Edition 01-2006

510-11

SECTION 510 - FRONT AXLE 3. The shim Sp to be arranged between outer bearing ring and differential mount is: Sp = 78 + [A - (B + D)] if D is positive or Sp = 78 + [A - (B - D)] if D is negative 5LA0295

17 where: 78 = Nominal value A = Measured dimension B = Nominal distance D = Value printed on the bevel pinion Round off to the lower figure. Example 1: 78 =Nominal value A = 14.1 mm. Dimension shown on the differential mount B = 90 mm. Nominal dimension D = +0.15 mm. Value printed on the bevel pinion Sp = 78 + [14.1 - (90 + 0.15)] = 1.95 mm Round off to the lower figure.

Example 2: 78 =Nominal value A = 13.9 mm. Dimension shown on the differential mount B = 90 mm. Nominal dimension D = -0.12 mm. Value printed on the bevel pinion Sp = 78 - [13.9 - (90 - 0.12)] = 2.10 mm Round off to the lower figure.

4. Insert the calculated shim Sp, fit the tapered bearings (2), the pinion (3) and the lock nut.

5LA0297

510-12

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE Pinion taper bearing preload adjustment

Proceed as follows: 1. Fit the bearing (1), the o-ring (2) and the ring nut (3). Preliminarily tighten the bevel pinion lock nut.

5LA0298

19 2. Use a plastic hammer to settle the pinion on the bearings. 3. Tighten the ring nut to reach a pinion rolling torque of: 1.4 - 1.8 Nm

5LA0299

20 4. Use a plastic hammer to settle the pinion on the bearings again. 5. Measure the rolling torque again and when the correct value is reached, rivet the edge of the ring nut into the pinion shaft grooves.

P/N 3681774M1

Edition 01-2006

510-13

SECTION 510 - FRONT AXLE Pinion and crown teeth clearance adjustment

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. Make sure that the clearance between the pinion and crown teeth is after assembly 0.10 - 0.25 mm to ensure the correct operation of the bevel gear.

Proceed as follows: 1. Apply sealant to the mount (1) as shown in the figure.

5LA0300

21 2. Fit on the mount (1) housings (2) and (3). Tighten the fastening screws at the specified torque of: 100 - 120 Nm

5LA0301

510-14

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE 3. Fit the ring nuts (1) and (2) and fasten to eliminate the differential float.

5LA0302

23 4. Position a dial gauge on the mount to measure the clearance between the pinion and ring teeth. Push the differential assembly against the ring nut. Either fasten or loosen the ring nut to obtain a clearance between pinion and ring teeth from 0.10 to 0.25 mm.

3LA0303

24 5. Turn the ring nut in the opposite direction to eliminate differential assembly float and ensure to the pinion a rolling torque of: 1.8 - 2.2 Nm 6. After assembly, check that the clearance between pinion teeth and ring is: 0.10 - 0.25 mm and that the differential rolling torque is: 2.5 - 3.5 Nm 7. After reaching the specified values, rivet the nut ring edges into the specific grooves.

P/N 3681774M1

Edition 01-2006

510-15

SECTION 510 - FRONT AXLE

FINAL DRIVE - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Drain oil from the side final drive. 2. Remove the screws (1) and remove the cover (2) with satellite holder housing levering on the two millings on the ring (3).

5LA0304

25 3. Remove the circlip (1) and remove the planetary gear set (2).

5LA0305

26 4. With the help of the tool, remove the nut ring (1) after removing the edge rivetted on the fork (2).

5LA0306

510-16

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE 5. Remove the crown (1) with the help of a lever.

5LA0307

28 6. Remove the ring (1).

5LA0308

29 7. Remove the three circlips (1) using a 8 MA screw, remove the three pins (2) with stop rollers from the cover (3).

5LA0309

30 8. Remove from the central hole the three satellites (1), the slewing bearings (2) and the respective roller bearings (3).

5LA0310

P/N 3681774M1

Edition 01-2006

510-17

SECTION 510 - FRONT AXLE Assembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the side final drive: - For orientation of parts, refer to the illustration on page 6. - Apply the tightening torques listed on page 100. -

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Proceed as follows: 1. Assemble by reversing the disassembly order. 2. Fit and tighten the nut ring (1) at the specified torque of: 360 - 400 Nm

5LA0311

510-18

P/N 3681774M1

Edition 01-2006

SECTION 510 - FRONT AXLE 3. Fit the cover (1) and tighten the fastening screws (2) at the specified torque of: 75 - 80 Nm The front axle toe-in adjustable through the steering track rod (3) must be: 0 Âą 4 mm measured on a diameter of 800 mm

5LA0312

P/N 3681774M1

Edition 01-2006

510-19

SECTION 510 - FRONT AXLE

510-20

P/N 3681774M1

Edition 01-2006

SECTION 600 POWER TAKE-OFF

SECTION 600 - POWER TAKE-OFF TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF REAR POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-4 SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-5 POWER TAKE-OFF COVER SEALANT APPLICATION DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-6 POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 600-12

600-2

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF

MAIN SPECIFICATIONS OF REAR POWER TAKE-OFF

Type (with two functions). . . . . . . . . . . . . . . . . . . . . .

1) independent in relation to the tractor’s ground speed or: 2) synchronised with the gearbox

Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

electrohydraulic with hydraulic, electro-hydraulically controlled clutch

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by switch on the operator's right.

Speed selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of a lever position on the operator's left

Spinning direction (tractor viewed from the rear) . . . . .

clockwise

Engine rate with PTO at 540 rpm . . . . . . . . . . . . . . . . Engine rate with PTO at 540E rpm . . . . . . . . . . . . . . .

(rpm)

2363

(rpm)

1697 13/8” (6 spines)

Diameter of the driven shaft on output spline shaft . . . Rotation rate with 540E rpm PTO synchronized with the gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P/N 3681774M1

Edition 01-2006

(rpm/ wheel turn)

10.769 (STD) 12.119 (GT)

600-3

SECTION 600 - POWER TAKE-OFF

DESCRIPTION AND OPERATION The power take-off (PTO) is characterised by the two-shaft transmission and a multiple plate wet hydraulic clutch. The hydraulic clutch is located on the rear end of the differential box and receives oil from the low pressure circuit. The oil before reaching the clutch crosses a hydraulic damper which modulates pressure to ensure a constantly gradual engagement. The switch on the console on the operator's right along with the two levers on the left can be used to operate all PTO functions. The engagement switch must be pressed and turned for reasons of safety to prevent involuntary engagement.

The PTO engages gradually and progressively. When disengaged, an electrohydraulic device stops PTO shaft rotation. The PTO has two basic speeds: - 540-540 ECO rpm - 540-1000 rpm A PTO proportional to advancement is available for special applications. The speed is selected by means of PTO selection levers: - PTO speed selection lever - PTO selection lever independent or proportional to tractor advancement.

CONTROLS 1

5LA0200

1 Rear PTO controls 1. PTO engagement switch 2. PTO speed selection lever

600-4

3. Proportional force PTO selection lever

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF

SECTIONS 1

5LA0199

3 2

PTO longitudinal section 1. 2. 3. 4.

PTO PTO PTO PTO

upper shaft hydraulic clutch output shaft gear (1000)

P/N 3681774M1

Edition 01-2006

5. PTO gear (540) 6. Proportional PTO gear 7. Proportional PTO shaft

600-5

SECTION 600 - POWER TAKE-OFF

POWER TAKE-OFF COVER SEALANT APPLICATION DIAGRAM

4LA0165

3 The types of sealant to apply are indicated in section 100.

600-6

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF

POWER TAKE-OFF Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Remove the power lift assembly.

5LA0201

4 2. Remove the PTO clutch cover. The brake pressure plate and three pistons will remain inside the cover.

5LA0202

5 3. Remove the clutch assembly (1) and the shaft (2).

5LA0046

P/N 3681774M1

Edition 01-2006

600-7

SECTION 600 - POWER TAKE-OFF 4. Loosen and remove the nut ring (1).

5LA0191

7 5. Remove the upper PTO shaft (1).

5LA0192

8 6. Extract the dual speed selection fork (2) spring pin (1).

5LA0193

9 7. Remove the dual speed selection control (1).

5LA0194

600-8

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF 8. Remove the proportional PTO gear (2) snap ring (1).

5LA0195

11 9. Using tool (1) 94 PTO GL extract the PTO output shaft (2).

5LA0204

12 10. Remove the cover (1).

1 5LA0196

13 11. Remove the proportional PTO shaft bearing (2) snap ring (1).

5LA0197

P/N 3681774M1

Edition 01-2006

600-9

SECTION 600 - POWER TAKE-OFF 12. Remove the differential housing lower cover and using a lever shift the proportional PTO shaft from its seat. 13. Remove the proportional PTO shaft (1) from the opposite side of the differential housing.

5LA0198

15 14. Position on the PTO clutch assembly on the working surface. 15. Remove the snap ring (1) and remove the shaft (2). Remove the brake steel plate (3).

2 5LA0205

16 16. Remove the snap ring (1) and the steel plate (2). Remove the sintered plate (3) and the steel plates (4).

5LA0203

600-10

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF 17. Using tool (1) 95 PTO GL remove the snap ring (2) and the spring (3).

5LA0208

18 18. Extract the piston (2) from the bell (1), using compressed air if needed.

1 2

5LA0207

P/N 3681774M1

Edition 01-2006

600-11

SECTION 600 - POWER TAKE-OFF Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the differential: - For orientation of parts, refer to the illustration on page 5. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 6. - Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Proceed as follows: 1. Fit the piston inside the clutch bell.

600-12

P/N 3681774M1

Edition 01-2006

SECTION 600 - POWER TAKE-OFF 2. Using tool (1) 95 PTO GL, refit the spring (2) and the snap ring (3).

5LA0206

20 3. Insert in the bell the clutch plates and fasten with the snap ring (1). Firstly insert a steel plate in contact with the piston and then a sintered plate and a steel plate.

5LA0209

21 4. Fit the brake steel plate and the input shaft fastening with the snap ring. 5. Position the proportional PTO shaft fastening it with the snap ring. 6. Fit the PTO output shaft and respective gear fastening it with a snap ring. 7. Position and fasten the shaft and the dual speed selection fork. 8. Fit the upper PTO shaft and fasten it with the respective snap ring. Tighten the nut ring to obtain a specified torque of: 215 - 250 Nm 9. Fit the clutch assembly and cover. 10. Fit the power lift assembly.

P/N 3681774M1

Edition 01-2006

600-13

SECTION 600 - POWER TAKE-OFF

600-14

P/N 3681774M1

Edition 01-2006

SECTION 700 HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT TABLE OF CONTENTS Description

Page

MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-5 MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-6 MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-7 HYDRAULIC CIRCUIT GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-8 Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-8 LOW FLOW RATE CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-10 HIGH DELIVERY CIRCUIT DESCRIPTION

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-12

STEERING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-14 HYDRAULIC PUMP DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-16 HYDRAULIC UNIT WITH THREE SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-17 HYDRAULIC UNIT WITH FOUR SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-18 HYDRAULIC UNIT WITH FOUR SOLENOID VALVES FOR FAST RUN . . . . . . . . . . . . . . . . . . . . . . . 700-19 HYDRAULIC UNIT WITH FIVE SOLENOID VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-20 DIFFERENTIAL LOCK FEEDING CIRCUIT DESCRIPTION (FRONT/REAR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-21 PTO AND PTO BRAKE FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-22 HI-LO HYDRAULIC FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-23 SPRING-ON FEEDING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-24 TRAILER BRAKE VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-25 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-25 TRAILER BRAKE VALVE (ITALIAN VERSION) . . . . . . . . . . . . . . . Step with trailer hitched and brake pedals released . . . . . . Step with trailer hitched and brake pedals applied . . . . . . . Step with parking brake applied and brake pedals released Release pressure inspection and adjustment . . . . . . . . . . . Release pressure inspection and adjustment . . . . . . . . . . .

. . . . . .

700-27 700-27 700-28 700-29 700-30 700-31

TRAILER BRAKE VALVE (EXPORT VERSION) . . . . . . . . . Step with trailer hitched and brake pedals released Step with trailer hitched and brake pedals applied . Release pressure inspection and adjustment . . . . .

. . . .

700-34 700-34 700-35 700-36

. . . .

SUPPLEMENTARY DISTRIBUTOR DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . 700-38 HYDRAULIC-MECHANICAL POWER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-39 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-39 PERSPECTIVE VIEWS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-40

700-2

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Power lift troubleshooting . . . . . . . . . . . . . . . . Power lift sealant application diagram . . . . . . . . Controlled position operation . . . . . . . . . . . . . . Controlled draft operation . . . . . . . . . . . . . . . . Mixed position and draft operation (Intermix) . . Floating operation . . . . . . . . . . . . . . . . . . . . . . Hydraulic distributor - Neutral step . . . . . . . . . . Hydraulic distributor - Delivery step . . . . . . . . . Hydraulic distributor - Exhaust step . . . . . . . . .

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

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

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

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

700-42 700-44 700-45 700-46 700-48 700-48 700-49 700-50 700-51

HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-52 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-52 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-55 HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-56 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 700-56 HYDRAULIC DISTRIBUTOR - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic inspections and adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Anti-shock valve inspection and adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discharge valve leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Check valve leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum valve inspection and calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Delivery pipe leakage inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . On-tractor power lift adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Position control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draft control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P/N 3681774M1

Edition 01-2006

700-60 700-60 700-62 700-63 700-64 700-66 700-67 700-68 700-70 700-72 700-72 700-73 700-74

700-3

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

700-4

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

double gear

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BX/DX

Model. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A510-F45-280

Engine/pump rpm ratio . . . . . . . . . . . . . . . . . . . . . . . . . .

1:1

Maximum operating pressure . . . . . . . . . . . . . . . . . . . . . .

(bar)

180 +5

Max. flow rate at 2500 engine rpm (high pressure). . . . . . .

(l/ rpm)

Max. flow rate at 2500 engine rpm (low pressure) . . . . . . .

(l/ rpm)

27.5

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

front right-hand side of engine

Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve system gears

Hydraulic/transmission oil quantity . . . . . . . . . . . . . . . . . . Oil type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(l)

35 Transfluid AS/B/C

Filters Type (on the intake) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

washable metallic simple cartridge

Type (delivery) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

replacement paper simple cartridge

P/N 3681774M1

Edition 01-2006

700-5

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS Steering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydrostatic distribution

Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BX/DX/OX

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orbitrol OSPC 80

Nominal cylinder 4 R. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(cm3/g)

Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(bar)

150 +5

Anti-shock valve calibration . . . . . . . . . . . . . . . . . . . . . . .

(bar)

200 +5

Steering cylinder type . . . . . . . . . . . . . . . . . . . . . . . . . . . .

double acting balanced MF

Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(mm)

35 x 57 x 204/2

Steering wheel turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . Steering wheel diameter . . . . . . . . . . . . . . . . . . . . . . . . .

4 (mm)

360

Hydraulic unit

700-6

Make. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

electrohydraulic

Low pressure valve calibration . . . . . . . . . . . . . . . . . . . . .

(bar)

Cooling circuit valve calibration . . . . . . . . . . . . . . . . . . . . .

(bar)

Forced lubrication valve calibration . . . . . . . . . . . . . . . . . .

(bar)

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT

MAIN TECHNICAL SPECIFICATIONS OF HYDRAULIC SYSTEMS Supplementary distributors Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HYX

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

standard-simple/double acting/ floating with automatic kick-out release

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with open centre and push-pull quick couplings

Calibration valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(bar)

180 +5

Maximum flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(l/ rpm)

Maximum quantity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection to the circuit . . . . . . . . . . . . . . . . . . . . . . . . .

in series

Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rear

Hydraulic-mechanical power lift Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MIX

Operating modes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

position/intermix draft control/ floating

Hydraulic system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

open-centre type

Standard cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

simple acting

Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(mm)

Supplementary cylinders . . . . . . . . . . . . . . . . . . . . . . . . .

Ø 90x116 two simple acting

Valve calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(bar)

180 +5

Anti-shock valve calibration . . . . . . . . . . . . . . . . . . . . . . .

(bar)

200 +5

P/N 3681774M1

Edition 01-2006

700-7

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT

HYDRAULIC CIRCUIT GENERAL DESCRIPTION The hydraulic circuit consists of two separate circuits fed by a two-stage gear pump (2A/2B) connected to the engine distribution from which it takes rotation motion. The two pump stages have a common feed. Oil is taken in through a 40 micron filter (1) arranged inside the gearbox casing which acts as hydraulic oil reservoir.

The two pump stages, with different sections, have different pressures and two separate conduits for high and low flow rates. The diagram below shows the assemblies fed by the hydraulic system, the low flow rate closed centre circuit (2A) and the open centre high flow rate circuit (2B).

Hydraulic circuit 1

11- -FILTER ON SUCTION FILTRO SULL'ASPIRAZIONE

2A FLOW RATE PUMP 2A-- LOW POMPA A BASSA PORTATA MAXIMUM FLOW RATE AT PORTATA MASSIMA AL MAX N. GIRI MOTORE MAX. ENGINE RPM 27,5l/min l / min 27.5

22 --DOUBLE GEAR PUMP POMPA DOPPIA AD FITTED ON RH SIDE OFMONTATA ENGINE INGRANAGGI SUL LATO DX DEL MOTORE

2B FLOW 2B--HIGH POMPA ADRATE ALTAPUMP PORTATA MAXIMUM FLOW RATE AT PORTATA MASSIMA AL MAX N. GIRI MOTORE MAX. ENGINE RPM 35 l/min. 0,55 I / min 55 l/min

3 - DELIVERY FILTER 3 - FILTRO IN MANDATA

SUPPLIED HYDRAULIC CIRCUITS CIRCUITI IDRAULICI ALIMENTATI 4 - HYDROSTATIC STEERING CIRCUIT 4 - CIRCUITO STERZO IDROSTATICO Max. working pressure 150± 5 bar pressione max. di lavoro 150 ± 5 bar STEERING CYLINDER 55 - -CILINDRO STERZO HYDRAULICIDRAULICA UNIT (low (Circuito pressureBassa circuit) 66 - -CENTRALINA Pressione)

SUPPLIED HYDRAULIC CIRCUITS CIRCUITI IDRAULICI ALIMENTATI

9 - TRAILER BRAKE VALVE 9 - VALVOLA FRENO A RIMORCHIO -SUPPLEMENTARY DISTRIBUTORSMAX.3 MAX. 3 1010- DISTRIBUTORI SUPPLEMENTARI MAXIMUM WORKING PRESSURE 180± 5 PRESSIONE MAX. DI LAVORO 180 ± 50 bar bar Make HYDROCONTROL SE/DE convertMarca HYDROCONTROL" ible, standard available convertibili SE/DE, with automatic disponibili standardrelease and floating position. Con sgancio automatico con posizione

flottante - FAST-RUN HYDRAULIC CLUTCH A A- FRIZIONE IDRAULICA FAST-RUN - DUAL DRIVE HYDRAULIC CLUTCH B B- FRIZIONE IDRAULICA DOPPIA TRAZIONE - DIFFERENTIAL LOCK (FRONT(ANT. C1 - C1 REAR C2) C2) C C- BLOCCAGGIO DIFFERENZIALE - POST. - HYDRAULIC PTO D D- P.d.F. IDRAULICA - HYDRAULIC BRAKE PTO E E- FRENELLO P.d.F. IDRAULICO - PTO CLUTCH MODULATING VALVEP.D.F. F F- VALVOLA MODULAZIONE FRIZIONE

-POWER LIFT CYLINDER 1212- CILINDRO DI SOLLEVAMENTO

- HYDRAULIC HI-LO GG- HYDRAULIC HI-LO

- LH OUTER CYLINDER 1313- CILINDRO ESTERNO SX

OIL COOLING CIRCUIT 77 - -CIRCUITO DI RAFFREDDAMENTO DELL'OLIO - COOLING CIRCUITDIVALVE 7 bar R R- VALVOLA CIRCUITO RAFFREDDAMENTO 7 bar GEARBOX LUBRICATION VALVEDEL (5 bar) 88 - -VALVOLA PER LUBRIFICAZIONE CAMBIO (5 BAR) -GEARBOX LUBRICATION 8A8A - LUBRIFICAZIONE DEL CAMBIO 8B -HI-LO LUBRICATION 8B - LUBRIFICAZIONE HI-LO

700-8

-POWER LIFT DISTRIBUTOR 1111- DISTRIBUTORE DEL SOLLEVATORE Max. working pressure 180 ± 5 bar Pressione max; di lavoro 180 ± 50 bar

-LH OUTERESTERNO CYLINDERDX 1414- CILINDRO -RH LEVELLING IDRAULICO HYDRAULIC DISTRIBUTOR 1515- DISTRIBUTORE (OPTIONAL) DI LIVELLAMENTO DX

(A RICHIESTA)

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0211

1 General hydraulic circuit

P/N 3681774M1

Edition 01-2006

700-9

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

LOW FLOW RATE CIRCUIT DESCRIPTION The transmission oil is take in by the inner pump stage (2A) and conveyed to the Orbitrol unit (4) according to high priority after crossing the filter (3). The Orbitrol thus supplied can either use the oil to feed the steering cylinder (5), controlled by the maximum valve (150 bars), or direct it towards the exhaust, i.e. the hydraulic unit feeding line (6). The unit (6) is always supplied also when the Orbitrol is empty by the pump, by unused oil or oil in excess. A closed centre circuit is formed inside the hydraulic unit (6) when pressure is kept constantly at 19.3 bars and controlled by the calibration valve. The circuit pressurised in this way ensures the correct pressure for activating the following units as needed: - - front and rear differential lock (C1-C2); - - intermediate PTO clutch (D);

700-10

- - PTO clutch (E); - - DTi engagement clutch (B); - - STr engagement clutch (A); - - hydraulic Hi-Lo (G). Each unit can be activated by separate electrohydraulic commands positioned inside the cab, either individually or in combination. The oil discharged by the units may return directly to the gearbox casing through a specific tube. The oil released by the calibration valve (19 bars) is let into a controlled cooling circuit by a 7 bars valve and after the radiator (7) it is conveyed to the transmission lubrication circuit (8a-8b-8c) controlled by the 5 bars calibrated valve. The 18.7 and 5 bar calibration valves are located inside the hydraulic unit (6).

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0212

2 Low flow rate circuit

P/N 3681774M1

Edition 01-2006

700-11

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HIGH DELIVERY CIRCUIT DESCRIPTION ÂŤ The pump (2B) after taking in appropriately filtered oil from the transmission, sends it in absolute priority to the trailer brake valve (9) and then to the supplementary distributors (10) and to the hydraulic power lift (11). The trailer brake valve, which incorporates a maximum valve calibrated at 130 bars, uses a very small part of the oil for the braking actions. The unused part is conveyed to the inlet plate of the supple-

700-12

mentary distributors where the maximum valve calibrated at 180 bars is located. The supplementary distributor can use all the oil flow from the pump for external units connected to it, in absolute priority with respect to the hydraulic power lift. The supplementary distributors outlet supplies the hydraulic lift via the distributor which incorporates a maximum valve calibrated at 180 bars and a safety valve calibrated at 200 bars.

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0213

3 High flow rate circuit

P/N 3681774M1

Edition 01-2006

700-13

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

STEERING CIRCUIT DESCRIPTION The low flow rate circuit consists of a first high pressure section for operating the hydraulic steering. The oil from the pump low flow rate stage (2a) crosses the filter (3) and feeds the Orbitrol steering distributor (4) to then power the respective steering cylinder (5). The oil discharged by the Orbitrol feeds the hydraulic unit (6) and through a low pressure circuit is directed to the various units.

700-14

The steering system fitted on the MF tractor series is hydrostatic: there is no mechanical connection between the steering wheel and the steering cylinder. Each minimum turn of the steering wheel corresponds to an equivalent turn of the wheels. If the engine breaks down or the hydraulic pump fails to operate, the Orbitrol acts like a hand pump operated by the steering wheel which allows steering.

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0214

4 Steering circuit

P/N 3681774M1

Edition 01-2006

700-15

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC PUMP DESCRIPTION AND OPERATION The hydraulic gear pump consists of a single block with two different stages, two suction channels and two separate delivery channels at different flow rates. The suction holes are made in the rear part of the pump and the delivery holes are found in the front. The delivery hole 2A feeds the low pressure circuit

(27.5 l/rpm), while the delivery 2B feeds the high flow rate circuit (55 l/rpm). Being connected directly to the engine, the pump is activated whenever the engine is running, taking in the filtered oil from the transmission and conveying it on both the low flow rate circuit and the high rate circuit at the same time.

5LA0215

5 Hydraulic pump 1. Double body pump 2A. Low flow rate stage 2B. High flow rate stage 3. O-ring 4. Pump drive gear

700-16

5. 6. 7. 8. 9.

Pump shaft Coupling flange Suction holes Low pressure delivery hole High pressure delivery hole

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC UNIT WITH THREE SOLENOID VALVES 1

VIEW FROM C

1 2 3 4

2 3

SPRING ON REAR PTO REAR PTO BRAKE DIFF LOCK

P L1

19,3 BAR

L2 M

7 BAR

5 BAR T

R in

R out

5LA0216

P/N 3681774M1

Edition 01-2006

700-17

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC UNIT WITH FOUR SOLENOID VALVES 1

VIEW FROM B

SPRING ON REAR PTO REAR PTO BRAKE DIFF LOCK SPEED SHIFT

1 2 3 4 5

2 3

P L1

19.3 BAR

L2 M

7 BAR

5 BAR T

R in

R out

5LA0217

700-18

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC UNIT WITH FOUR SOLENOID VALVES FOR FAST RUN 1

B B

VIEW FROM B

1 21 32 43 54 65

3 4 3 4

BE-SPEED DT REAR PTO REAR PTO BRAKE DIFF LOCK

1 2 6

1 2

P P

L1 L1

19,3 BAR 19,3 BAR

PS PS

7 BAR 7 BAR

5 BAR 5 BAR T T

T1 T1

T2 T2

L2 L2 R in R in

R out R out

5LA0218

P/N 3681774M1

Edition 01-2006

700-19

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC UNIT WITH FIVE SOLENOID VALVES 1

VIEW FROM B

BE-SPEED DT REAR PTO REAR PTO BRAKE DIFF LOCK SPEED SHIFT

1 2 3 4 5 6

3 4

1 2

P L1

19,3 BAR

L2 M

7 BAR

5 BAR T

R in

R out

5LA0219

700-20

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

DIFFERENTIAL LOCK FEEDING CIRCUIT DESCRIPTION (FRONT/REAR) The front and rear differential is locked by shifting two mechanical engagements operated by a piston fed by pressurised oil at 18 bars. This occurs when the driver presses the control button (1) and energises the concerned solenoid valve (BLc) fitted on the unit (2). Energising makes the solenoid valve open the simultaneous oil feed to the rear (3) and front (4)

lock. The differential is released when by means of the brake pedals (5) the solenoid valve (BLc) is deenergised, closing the oil feed and opening communication with exhaust. The inner springs recall two block mechanisms in home position deactivating the action on the two respective differentials.

5LA0220

P/N 3681774M1

Edition 01-2006

700-21

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

PTO AND PTO BRAKE FEEDING CIRCUIT DESCRIPTION The PTO is engaged when the pressurised oil at 18 bars feeds the hydraulic piston making integral the plates and inter plates of the wet hydraulic clutch (1) thus transmission motion from the engine to the rear tractor PTO shaft (2). When the PTO / FRn solenoid valve is energised, the oil from the unit (6) via the tube (5) crosses the regulating valve (4), comes into communication with the accumulator (3) and engages the PTO. The PTO clutch is disengaged when the solenoid valve is de-energised by the control knob. A brake system consisting of a plate and three hydraulic actuators is provided to eliminate the possible rotation of the PTO shaft due to dragging of the wet plates. The actuators are fed at the same 18 bars pressure

via the same solenoid valve (PTO/FRn) but via a different outlet hole (FRn) and different piping, alternative to the clutch feed (PTO). When not energised (i.e. then the PTO clutch is not powered), the solenoid valve (PTO/FRn) feeds oil to the three PTO brake pistons. Therefore the solenoid valve (PTO/FRn) when energised operates the PTO clutch and releases the PTO brake, while when it is not energised feeds the PTO brake pistons and releases the PTO clutch. The accumulator (3) consists of a hollow cylinder (8), a piston (9), a spring (10) and a cover (11) with a stop ring (12). The hole (13) is connected to the PTO feeding pipe and lets oil into the cylinder into contact with the piston (9) exerting pressure accumulation.

5LA0221

700-22

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HI-LO HYDRAULIC FEEDING CIRCUIT DESCRIPTION The electrohydraulic Hi-Lo command allows a 20% speed reduction by pressing a button located on the gear lever. When the solenoid valve (A) is energised, oil is supplied to the Hi-Lo unit (B) causing the engagement of high gear ranges because the oil pressure locks

the hydraulic clutch and releases the brake allowing direct motion take-off. De-energising the solenoid valve takes the oil pressure to 0 bars allowing the operation of the planetary gear reducer: this reduces the speed by 20% and provides low gear ranges.

5LA0222

P/N 3681774M1

Edition 01-2006

700-23

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

SPRING-ON FEEDING CIRCUIT DESCRIPTION A spring-on DT release system is provided as an alternative to the DT with hydraulic clutch. The spring-on is a mechanical engagement device for the four drive wheels with hydraulically controlled release.

4WD is always engaged when the tractor engine is stopped to ensure perfect braking. De-energising the solenoid valve (A) allows oil at a pressure of 18 bars to disengage 4WD by axially shifting the sleeve (11) from position (X) to position (Y).

5LA0223

700-24

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

TRAILER BRAKE VALVE Description and operation The trailer brake valve (1) is fitted on the back of the tractor and feeds the trailer via the oil union (2). The oil reaching the valve has absolute priority with respect to the high flow rate circuit. The oil not used by the trailer brake is sent to the supplementary distributors (2).

5LA0224

14 The trailer brake is activated at the same time as the tractor brakes and when the dashboard indicator (1) lights up.

5LA0225

15 The tractor may be equipped with two types of valves: 1. Trailer valve (Italian version) 2. Trailer valve (export version) The trailer valve (Italian version) presents with respect to the export version a supplementary device in the lower part with a tie-rod connected to the parking brake. This is because Italian legislation requires trailers to be equipped with a self-braking device. This must ensure application of the trailer brakes when disconnected from the tractor. Furthermore, this braking mechanism must come into action when the tractor stops and the parking brake is applied. Consequently, to tow the trailer, a flow of oil must be maintained on the trailer brake mechanism at a constant pressure in the 10-15 bars range to keep the mechanical brakes released.

P/N 3681774M1

Edition 01-2006

700-25

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Proceed as follows in presence of the Italian version trailer valve for correct and safe removal and refitting of the flexible brake tube of the trailer from/to the union (2, fig. 14) on the back of the tractor. WARNING

This operation is extremely important and must be performed always before and after the trailer is unhitched from the tractor because this ensures the immediate intervention of the automatic safety braking system equipping the trailer braking system by law.

The trailer-tractor connection tube removal-refitting operation can be performed with either the engine stopped or running: - with engine stopped: there is no problem for engaging and disengaging because there is no oil pressure in the circuit. - with engine running: always apply the handbrake because this will ensure that there is no pressure in the brake circuit.

700-26

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT

TRAILER BRAKE VALVE (ITALIAN VERSION) Step with trailer hitched and brake pedals released The oil from the pump crosses pipe “P” to groove “C” proceeding on one side of the channel “R” to reach and in this way feed, through chamber “H”, the trailer and release the self-braking device. The same oil from the pump crosses groove “C” and is also put into communication with the pipe “N” to feed the power lift.

This is ensured by the position assumed by the main piston “Q”. Spring “G1”, acting on the latter, maintains a constant pressure around 10-15 bars needed to deactivate the trailer brake.

Q G2

K G1

5LA0226

16 A. Trailer brake connection quick connection B. Distributor activation piston C. Pump-power lift connection groove D. Chamber E1. Pressure switch E2. Pressure switch F. Chamber G. 140 bar pressure hold spring G1. 10-15 bar pressure hold spring G2. Sleeve return spring (W) G3. Piston spring (L) H. Trailer brake outlet chamber K. 10-15 bar pressure adjustment shims

P/N 3681774M1

Edition 01-2006

K1. Piston stroke adjustment shims (Q) K2. 140 bar pressure adjustment shims L. Trailer brake feeding command piston M. Parking brake connection tie-rod N. Power lift feeding O. Return piston P. Pump feed Q. Main piston R. Trailer brake feeding channel S. Brake tie-rid inner channel T. Discharge channel W. Sleeve Y. Tractor brake feed

700-27

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT Step with trailer hitched and brake pedals applied The oil from the brake pedal shifts the piston “B” which thus compresses the spring “G” and shifts the main piston “Q”. This movement conveys the pressurised oil entirely into the channel “R” and then, through the groove “F”, to chamber “H”, thus feeding the trailer brake at a pressure of max. 140

bars. Having obtained the braking action, the increased pressure shifts the piston “O” which returns the main piston “Q” to neutral position reopening the passage to the channel “N” for feeding the power lift.

Q G2

K G1

5LA0227

17 A. Trailer brake connection quick connection B. Distributor activation piston C. Pump-power lift connection groove D. Chamber E1. Pressure switch E2. Pressure switch F. Chamber G. 140 bar pressure hold spring G1. 10-15 bar pressure hold spring G2. Sleeve return spring (W) G3. Piston spring (L) H. Trailer brake outlet chamber K. 10-15 bar pressure adjustment shims

700-28

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT Step with parking brake applied and brake pedals released By activating the parking brake via the tie-rod “M”, communication is effected between the exhaust “T” and the chamber “S” inside the tie-rod; being the latter connected to the chamber “H” which feeds the trailer, has practically no pressure. The auto-

matic trailer braking device is released in this way. The oil from the pump, in addition to being conveyed into chamber “D”, feeds the hydraulic power lift via the pipe “N” put into communication by groove “C”.

Q G2

K G1

M G3 L

5LA0228

18 A. Trailer brake connection quick connection B. Distributor activation piston C. Pump-power lift connection groove D. Chamber E1. Pressure switch E2. Pressure switch F. Chamber G. 140 bar pressure hold spring G1. 10-15 bar pressure hold spring G2. Sleeve return spring (W) G3. Piston spring (L) H. Trailer brake outlet chamber K. 10-15 bar pressure adjustment shims

P/N 3681774M1

Edition 01-2006

700-29

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Release pressure inspection and adjustment Adjust as follows if the pressure measured using a pressure gauge applied to the trailer brake connector is not included in the range from 10 to15 bars.

WARNING

Wait for the pressure in the hydraulic circuit to drop to zero before starting.

WARNING

Sprays of hot pressurised fluid may cause severe lesions and burns. Use the appropriate safety devices.

1. Remove the tractor valve by disconnecting all the tubes. Protect all the holes to avoid letting in dirt and dust. 2. Remove the piston cover (1).

5LA0229

19 3. Extract the complete piston (1) from the valve body. During this operation, keep the piston in horizontal position to prevent components from falling into the valve.

5LA0230

700-30

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 4. Remove the slewing bearing (1), the spring (2) and the spring (3) from the piston (4). Add or remove the shims (5) considering that a variation of 1 mm will vary the pressure by approximately 1.5 bars with the engine at 900 1000 rpm.

5LA0231

21 5. Refit the valve by reversing the removal sequence. 6. Connect the pressure gauge to the trailer brake connection again and check that the working pressure is 10 -15 bars. Repeat the operations above if it is not. Release pressure inspection and adjustment Adjust as follows if the braking pressure measured using a pressure gauge applied to the trailer brake connector is not 140 bars.

WARNING

Wait for the pressure in the hydraulic circuit to drop to zero before starting.

WARNING

Sprays of hot pressurised fluid may cause severe lesions and burns. Use the appropriate safety devices.

1. Remove the tractor valve by disconnecting all the tubes. Protect all the holes to avoid letting in dirt and dust.

P/N 3681774M1

Edition 01-2006

700-31

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 2. Remove the piston cover (1).

5LA0229

22 3. Extract the complete piston (1) from the valve body. During this operation, keep the piston in horizontal position to prevent components from falling into the valve.

5LA0230

23 4. Remove the slewing bearing (1), the spring (2) and the spring (3) from the piston (4).

5LA0232

700-32

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 5. Fit the piston (1) on the tool (2) 171 IDR GL to compress the inner spring (1, fig. 26) and facilitate cap disassembly (2, fig. 26).

5LA0233

25 6. Loosen the cap (1), extract the spring (1) and add or remove the shims (3) considering that a variation of 1 mm will vary the pressure by approximately 10 bars with the engine at 900 1000 rpm.

5LA0234

26 7. Refit the valve by reversing the removal sequence. 8. Connect the pressure gauge to the trailer brake connection again and check that the working pressure is 140 bars. Repeat the operations above if it is not.

P/N 3681774M1

Edition 01-2006

700-33

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT

TRAILER BRAKE VALVE (EXPORT VERSION) Step with trailer hitched and brake pedals released The oil is sent from the pump through pipe “P” and via groove “C” it proceeds via pipe “N”, thus feeding the hydraulic power lift. There is no pressure in the oil in chamber “H” being

in communication with discharge “T” via groove “R” and the chamber of spring “G”. During this step, no braking device is applied to the trailer.

Q G

5LA0235

27 A. B. C. G. H. J. N.

700-34

Trailer brake connection quick connection Distributor activation piston Pump-power lift connection groove 140 bar pressure hold spring Trailer brake outlet Cap To power lift

O. P. Q. R. T. Y.

Return piston From pump Distributor main piston Trailer brake feeding groove To exhaust From tractor brakes

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT Step with trailer hitched and brake pedals applied Oil from the brake pedals shifts piston “B” which thus shifts the spring compression “G” and shifts the main piston “Q”. This movement allows the oil from the pump to be entirely conveyed via pipe “P” to groove “R” to reach chamber “H” thus feeding the trailer brake up

to a maximum pressure of 140 bars. Having obtained the braking action, the increased pressure shifts the piston “O” which returns the main piston “Q” to neutral position reopening in this way the passage to the channel “N” for feeding the hydraulic power lift.

Q G

O R

5LA0236

28 A. B. C. G. H. N.

Trailer brake connection quick connection Distributor activation piston Pump-power lift connection groove 140 bar pressure hold spring Trailer brake outlet To power lift

P/N 3681774M1

Edition 01-2006

O. P. Q. R. T. Y.

Return piston From pump Distributor main piston Trailer brake feeding groove To exhaust From tractor brakes

700-35

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Release pressure inspection and adjustment Adjust as follows if the braking pressure measured using a pressure gauge applied to the trailer brake connector is not 140 bars.

WARNING

Wait for the pressure in the hydraulic circuit to drop to zero before starting.

WARNING

Sprays of hot pressurised fluid may cause severe lesions and burns. Use the appropriate safety devices.

1. Wash the valve carefully and leave it fitted on the tractor. 2. Loosen and remove the quick coupling (1).

5LA0237

29 3. Extract from the valve body the sleeve (1) and the piston (2).

5LA0238

700-36

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 4. Fit the piston (1) on the tool (2) 171 IDR GL to compress the inner spring (1, fig. 26) and facilitate cap disassembly (2, fig. 26).

5LA0233

31 5. Loosen the cap (1), extract the spring (1) and add or remove the shims (3) considering that a variation of 1 mm will vary the pressure by approximately 10 bars with the engine at 900 1000 rpm.

5LA0234

32 6. Refit the valve by reversing the removal sequence. 7. Connect the pressure gauge to the trailer brake connection again and check that the working pressure is 140 bars. Repeat the operations above if it is not.

P/N 3681774M1

Edition 01-2006

700-37

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

SUPPLEMENTARY DISTRIBUTOR DESCRIPTION AND OPERATION The distributors are powered simultaneously: activation of either one or the other blocks the feed of oil to the next distributors and to the power lift thus preventing contemporary operation. An optional flow baffle may be fitted on the inlet body (E) to divert the flow to the first distributor conveying the remaining oil flow from the pump to a second distributor or to the hydraulic power lift. The following distributor versions are provided: - standard simple and double acting distributor - automatic release simple and double acting distributor - floating position simple and double acting distributor - hydraulic motor distributor

The supplementary distributors are fitted on the central rear side of the tractor, fastened to the hydraulic power lift body and used to control the outer jacks. They are combined with the hydraulic power lift circuit and use the same transmission oil from an open centre circuit. The supplementary distributor control levers are arranged on the console on the right of the driverâ&#x20AC;&#x2122;s seat. The rods of the distributors themselves are operated by means of a flexible cable. This consist of an inlet body (E) where oil is sent by the pump (P) in priority via the 180 bar calibration valve (V), from one or more elements (up to a maximum of three) and the outlet body (U) from which departs the hydraulic power lift feeding pipe (S). 1

180 b

5LA0239

700-38

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC-MECHANICAL POWER LIFT Description and operation The tractor hydraulic-mechanical power lift is connected by appropriate tie-rods to the external implements which are raised and lowered. It consists of a lifting body, one or more double acting cylinders and two external levers which control a hydraulic distributor. A special Load Sensing distributor ensures smooth movements and controls without jerks when moving upwards. The power lift has four operating modes: - controlled position operation

- controlled draft operation - mixed position and draft operation - floating operation The hydraulic distributor governs three different steps: - delivery or lifting step - neutral step - discharge or lowering step. A descent speed regulator provides full control by the operator and hydraulically blocks the system during transportation.

5LA0240

34 1. 2. 3. 4. 5. 6.

Pivoting support Power lift unit Power lift arm Arm holder shaft Command distributor Cylinder

P/N 3681774M1

Edition 01-2006

7. 8. 9. P. S.

Draft control lever Controlled position lever fitted on power lift Control draft rod P - Controlled position lever on control selector S - Draft control lever

700-39

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT PERSPECTIVE VIEWS 1

5LA0241

Hydraulic-mechanical power lift 1. 2. 3. 4. 5. 6.

700-40

Pivoting support Power lift unit Power lift arms Arm holder shaft Command distributor Cylinder

7. Draft control lever 8. Controlled position lever 9. Controlled draft tie-rod 10. Inner lever unit 11. Cylinder 12. Arm control wheel

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0242

Hydraulic valve system 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17.

Rubber guard Nut Dowel Screw Calibration valve ball Spring guide plate Calibration valve spring Spring guide Regulator piston Regulator piston spring Spring holder cap Supporting shim Retainer plate Screw Control rod Control rod spring Nut

P/N 3681774M1

Edition 01-2006

18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34.

Dowel Supporting shim Anti-shock valve spring Anti-shock valve ball Complete discharge valve Discharge valve Discharge valve spring Cap Choking spring with hole Valve system casing Check valve Check valve spring Valve seat Block valve and descent control Roller Valve body and control assembly Upper lid

700-41

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Power lift troubleshooting Faults

Possible causes

Remedies

The power lift does not keep the load raised (with the engine running the height swings rhythmically; when the engine is stopped the load is lowered).

1. Faulty check valve tightness

Remove, check, clean and if required replace the concerned parts.

2. Oil leakage through the distributor pin seat seals.

Replace the seals.

3. Faulty distributor pin tightness.

Remove and check tightness. Replace the distributor pin and respective seat if faulty.

4. Oil leakage through lifting piston seal or through cylinder oil delivery union seals.

Replace the seals.

5. Fault sealing or very low calibration of cylinder safety valve.

Replace the valve.

The overpressure valve trips when the lifting arms are raised to the maximum.

1. Incorrect setting of lifting arm stroke.

Adjust correctly.

Low lifting capacity.

1. Incorrectly calibrated overpressure valve.

Replace the valve.

2. Incorrectly calibrated cylinder safety valve.

Replace the valve.

3. Poor pump performance (generally accompanied by long lifting time).

Overhaul or replace the pump.

1. Obstructed oil filter.

Replace the filter.

2. Control valve jammed in the discharge position.

Release the control valve.

3. Faulty hydraulic pump.

Overhaul or replace the pump.

The power lift does not raise.

700-42

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

The power lift jerks.

1. Obstructed oil filter.

Replace the filter.

2. Air infiltration along the pump suction pipe.

Check tightness of unions and efficiency of seals.

1. Obstructed oil filter.

Replace the filter.

2. Oil leaks through the seals, with consequent drop in pressure: piston or cylinder deliver union seals.

Replace the faulty seals.

3. Faulty hydraulic pump.

Overhaul or replace the pump.

The power lift moves down too slowly.

1. Incorrect arm speed setting.

descent

Adjust correctly.

The power lift moves down too fast.

1. Incorrect arm speed setting.

descent

Adjust correctly.

The power lift raises too slowly.

P/N 3681774M1

Edition 01-2006

700-43

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Power lift sealant application diagram

5LA0243

37 The types of sealant to apply are indicated in section 100.

700-44

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Controlled position operation Position the draft control lever (S) against the stop in the bottom of the sector: the roller (12) sliding on the rocker arm (13) and the draft cam (11) moves away. In this way, the draft levers do not effect controlled position operation. The arms are raised by moving the position control lever (P) upwards. The linkages work as follows. The crank (3) integral with the shaft (2) turns anticlockwise making the roller (4) slide on the position cam (5). This causes the rocker arm clockwise rotation (13) via the shock absorber (15) transmits an anticlockwise rotation to the transmission lever (16 and 1), taking the distributor rod (18) to delivery position (c) with consequent lifting of the arms.

During the lifting movement of the arms, the crank (9) and pin (7), turning anticlockwise via the shackle (8), turn the position cam (5) clockwise. The rocker arm (6) can turn anticlockwise when the roller (4) meets the slanted surface of the cam (5). This via the shock absorber (15) turns anticlockwise the transmission lever (16-1), pushed by the spring of the distributor rod (18) which shifts to neutral position (n), thus stopping the arm movement. When moving the arms down, the linkages move in the opposite direction. The arm position, both moving up and down, corresponds to a certain position of the position control lever (P) on the sector.

5LA0244

P/N 3681774M1

Edition 01-2006

700-45

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Controlled draft operation By positioning the position control lever (P) against the stop on the bottom of the selector, the crank (3, fig. 38) reaches its extreme anticlockwise rotation position. In this position, the roller (4, fig. 38) moves fully down from the slanted surface of the position cam (5, fig. 38) allowing the anticlockwise rotation of the rocker arm (6, fig. 38) and the clockwise rotation of the transmission lever (15-1), pushed by the spring of the rod (16) which is in small discharge position (s). In this way, the position levers do not effect controlled draft operation. By positioning the control lever (S) against the stop on the top of the sector, the draft shaft (3) is turned clockwise. The crank (4) integral with the shaft (3) reaches its extreme rotation position and via the tie-rod (5) shifts the roller (10) which reacts on the draft cam (9) turning clockwise the rocker arm (11) which, via the shock absorber (14) turns the transmission lever anticlockwise (15-1), thus taking the distributor rod (16) to loading position (c) with consequent lifting of the arms. The arms stop only when the piston comes into contact with the end-of-stroke pin (13). This, by means of the tie-rod (12) turns the lever clockwise (15-1), compressing the shock absorber spring (14) and thus leaving the rod (16) free to shift from natural position (n) where it is pushed out by the spring. Shifting the control lever (S) down the linkages causes the following: The crank (4), integral with the draft shaft (3),

700-46

turns anticlockwise and by means of the tie-rod (5) makes the roller (10) slide on the rocker arm (11). The roller (10), when it encounters the slanted surface of the draft cam (9) allows the anticlockwise rotation of the rocker (11) which with the shock absorber (14) turns the transmission lever (15-1) anticlockwise, thus leaving the distributor rod (16) free to move to neutral position (n). Continuing to move the lever (S) down to discharge position (s) makes the arm lower. Indeed, in the initial part of the downward stroke, the draft control lever (S) does not manifest the corresponding arm lowering. The traction effort on the third point (6) stresses the tie-rod (7) in the direction indicated by the arrow (RP) making the crank (8) turn clockwise and the draft cam (9) fastened on to the same pin. When the slanted surface of the draft cam (9) encounters the draft cam (9), the anticlockwise rotation of the rocker (11) is obtained. This along with the shock absorber (14) turns the transmission lever (15-1) anticlockwise, thus leaving the distributor rod (16) in neutral position (n) and stopping the arm movement. With the increased traction effort, the draft cam (9) moves the roller (10), thus increasing the movement above. The distributor rod (16) moves from neutral position (n) to loading position (c), consequently raising the arms. When the traction effort decreases, the rod (16) returns either to neutral or lowered position by reversing the linkage movement with respect to that shown.

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0245

P/N 3681774M1

Edition 01-2006

700-47

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Mixed position and draft operation (Intermix) Proceed as follows to use the power lift in this condition: Rest the position control lever (P) on the stop on the bottom of the sector to obtain maximum working depth. Determine the minimum depth required by means of the draft control lever lifting it from zero position, so that the roller (10) reacting with the draft cam (9) takes to lifting position (c) the distributor stem (1) and determines a further upward shift of the lifting arms. Due to the position previously established with the control lever in position (P), the rocker arm (11), the roller (4, fig. 38) and the position cam (5, fig.

38) prevent the rod (16) from going to the lowered position (s) and therefore the arms cannot be lowered also when the traction effort on the third point (6) tends to decrease, thus stressing the tie-rod (7) in the direction of the arrow (RN). This condition does not prevent the power lift from working in controlled draft mode if in the presence of harder soil the traction effort on the third point (6) tends to increase, stressing the tie-rod (7) in the direction of the arrow (RP). Therefore, the mixed position and draft control limits downward depth variations characteristic of controlled draft use, thus ensuring the required maximum working depth.

Floating operation In floating position, the lifting arms are free to move up or down following the unevenness of the soil on which the implement rests. Proceed as follows to use the power lift with this function:

a) Take the lever (P) to control position in the bottom of its sector against the lower stop. b) Take the draft control lever (S) downwards in its sector to obtain floating operation and allowing the implement to float on the soil profile.

5LA0245

700-48

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Hydraulic distributor - Neutral step During this step, the control distributor keeps the oil contained in the cylinder under pressure, allowing the oil from the pump to flow freely to the transmission casing. During this step, the control rod (19) is in such a position to connect the chamber (16) directly to the exhaust via the hole (18). The oil from the pump thus moves the regulator piston (10) downwards, feeds the chamber (9), opens the holes (17) entering inside the annular conduit (22) and then proceeds to the transmission

casing. The oil contained in the chamber cylinder (26) remains pressurised because it is withheld by the check valve (24), by the relief valve (6) and by the safety valve (14) which are connected to the cylinder from the annular conduit (11) and therefore supports the load applied to the lifting arms. The anti-shock safety valve (14) protects the cylinder from overpressure.

Static pressure oil Oil from pump Discharged oil (pressure 0 bars) 5LA0246

P/N 3681774M1

Edition 01-2006

700-49

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Hydraulic distributor - Delivery step During this step, the control distributor sends pressurised oil to the cylinder and consequently lifts the arms; the control rod (11) connects chamber (8) to the oil from the pump via the annular conduit (6) and the holes (1) and (2). In this way, the chambers (8) and (4) are influenced by the same pressure and the regulator piston (3) closes the exhaust holes (9) pushing upwards the return spring. Pressurised oil thus goes to the cylinder passing through the annular conduit (6) entering the hole (1) through the fixed chocking (15) and the variable chocking created by the control rod (11) with the hole (2), opens the check valve (17) enters the annular conduit (5) and feeds the cylinder chamber

(19). The regulator piston (3) governs the oil flow from the cylinder because the chambers (8) and (4) are subjected to the difference of pressure created by the passage of oil through the fixed choking (15) and the variable chocking created by the control rod (11) according to its upward shift by effect of the power lift internal linkages. The flow in excess is relieved at the lifting pressure through holes (9) thus regulating the maximum lifting speed and allow slow lifting arm departure and arrival. During this step, the maximum lifting pressure is controlled by the calibration valve (13) which is connected to the annular conduit (6) via the holes (1) and (2).

Pressurised oil Discharged oil (pressure 0 bars)

5LA0247

700-50

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Hydraulic distributor - Exhaust step During this step, the control distributor makes exhaust flow away along with the oil from the pump and the oil from the cylinder with consequent lowering of the lifting arms. The control rod (12) is in such a position to connect the chamber (9) directly to the exhaust via the hole (11). The oil from the pump, as during the neutral step, shifts the regulator piston (5) downwards and discharges the oil from the holes (10). At the same time, the oil from the chamber cylinder

(15) to the annular conduit (14) crosses from the descent speed control valve (1) and via the hole (3) enters into the discharge valve chamber (4) going to the exhaust from the hole (6) causing the lowering of the lifting arms. During this step, the descent speed of the implement may be adjusted with the manual lever (2), fastening to decrease the descent speed. For safe transfer on roads and preventing accident operation of the power lift control levers, secure the lever (2) fully against the valve (1) in its seat.

Oil from pump Discharged oil (pressure 0 bars) 5LA0248

P/N 3681774M1

Edition 01-2006

700-51

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

1. Position the power lift on a work bench. 2. Loosen the fastening screws and remove the cylinder (1).

5LA0249

44 3. Loosen the fastening screws and remove the complete hydraulic distributor (1).

5LA0250

45 4. Disconnect the draft transmission tie-rod (1) by loosening the screw (2) and the lock nut (6). Arrange the pivoting support (5) by removing the hinge pin (4) after removing the snap ring (3). Loosen the screws (8) and remove the reaction spring (7) with its cover.

5LA0251

700-52

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 5. Remove the snap rings (1) and (2) from the respective inner linkage support pins. Loosen and arrange the two hexagonal support pins (3) and (4), after removing a second snap ring on the pin (4) against the rocker arm (5). Remove the lever unit with the rocker (5), the stop pin (6), the linkage (7), the transmission lever (8), the spring guide pin and the shim with screw (9) for operating the hydraulic distributor.

5LA0252

47 6. Loosen the threaded dowels (1) and (2) then remove the cam (3) and the position connecting rod (4) with the transmission shackle (5), hinged onto the pin (6);

5LA0253

7. Remove the draft cam fastening spring pin (1) and remove it from the pin (2). Arrange the draft crank (3) with the linkage (4) and the guiding shackles (5). Remove the snap ring (6) then remove the pin (2) with the draft transmission linkage.

5LA0254

5LA0255

P/N 3681774M1

Edition 01-2006

700-53

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 8. Loosen the two fastening screws (1) of the control lever supports (2) and (3) and remove all with the two position (4) and draft (5) shafts positioned one against the other then separate them.

5LA0256

51 9. Remove the two snap rings (1) holding the lifting arms (2), remove them making a reference mark for correct refitting on the shaft (3). Loosen the threaded retainer dowel (4), then remove the shaft (3) from the left of the power lift body: this will drag the left o-ring (5). Remove and arrange the push arm (6) along with the respective connecting rod.

5LA0257

700-54

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Adjustments 1. Check the perfect state of all removed components, as well as the perfect mobility of all linkages, stops, and pins. 2. Check adjustment of spring guide pin (1). The position must be: Y = 59.5 mm Check distance between screw head (2) and the valve cap (3). The position must be: X = 15 - 15.5 mm

5LA0258

53 3. For correct assembly of the reaction spring (1) follow the indications below: - The spring pusher (2) must not overcome the spring but be fastened so that the spring can turn on its axis without float. -

Dimension (L) forming the cover (3) fitted on the power lift body must be the same as the dimension measured on the spring pack. If this does not occur, replace the washer (4) with a suitable shim. 5LA0259

54 4. Replace all the shaft support bushings for arm holders (3) as well as the o-rings (5), copper seals, snap rings (1) and spring pins.

5LA0257

55 5. Carefully wash and clean the power lift body and all internal components to be refitted on the power lift body itself.

P/N 3681774M1

Edition 01-2006

700-55

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC-MECHANICAL POWER LIFT OVERHAUL Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the power lift: - For orientation of parts, refer to the illustration on pages 39 and 40. - Before refitting the housings, supports and covers, thoroughly clean and degrease the coupling surfaces and apply a strip of sealant about 2 mm in diameter as indicated in the figure on page 44. - Apply the tightening torques listed on page 100.

700-56

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Proceed as follows: 1. Arrange the lifting shaft (1) in its seat on the power lift body, insert the push arm (2) and correctly align the hole with the fastening dowel seat (3), fasten and tighten the dowel. Fit in the respective seats the two o-rings (4) of the power lift shaft using tool 119a SOL-GL. Insert the lifting arms (5) into the coupling on the shaft (1) aligning them with the reference made during disassembly when fitting the two retainer snap rings. Lubricate the mobile parts, hinged and removed, to obtain perfect mobility and sliding of the linkage.

5LA0260

2. Temporarily position on a bench with the help of appropriate supports the entire linkage and the power lift components. Arrange them as far as possible in their real working position for better visibility and familiarity.

5LA0261

57 3. Place on the power lift body, the first control linkage components (controlled draft) arranging them in their real and correct position.

5LA0262

P/N 3681774M1

Edition 01-2006

700-57

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

4. Arrange on the power lift body. Then refit and connect the draft cam (1) pins.

5LA0263

5LA0264

5. Perform the same procedure on the controlled position linkages and then arrange on the power lift in definitive position.

5LA0265

5LA0266

700-58

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

6. Present the complete rocker arm linkage assembly (1) with the tie-rods, levers and hydraulic distributor actuator pins, correctly arranged and then arrange on the cover making sure that the adjustable valve cap (2) is in its circular seat on the power lift body. At the same time, arrange the lower arm of the rocker (1) underneath with the contact rollers arranged on the position connecting rod cam (3), not forgetting to position the snap ring in contact with the rocker (1). Arrange the hydraulic distributor (4) in its seat on the power lift body and fasten it with the respective screws.

5LA0267

5LA0268

64 Check that the linkage movements are correct after each operation and that there are no improper interferences. Arrange all the snap rings, the pins and threaded dowels. Tighten the various fastening screws. 7. Position the cylinder with the respective piston (2) and new o-ring (3). Tighten fastening screws at 120 Nm.

5LA0269

P/N 3681774M1

Edition 01-2006

700-59

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

HYDRAULIC DISTRIBUTOR - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Loosen the fastening nuts and loosen the two adjustment dowels (1) and (2) of the calibration valve and anti-shock valve respectively, to decrease the push of the respective springs outwards. Remove the retainer plate (3) by loosening the three fastening screws (4) with the control rod (5) and respective recall spring.

5LA0270

66 2. Loosen from its seat the cap (1), the spring (2) and the regulator piston (or servo valve) (3).

5LA0272

67 3. Remove from its seat the calibration valve components, i.e. the spring guide (1), the spring (2), the spring plate (3) and the ball (4). Remove from its seat the anti-shock valve components, i.e. the lower and upper plate (5), the spring (6) and the ball valve (7).

5LA0274

700-60

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

4. Turn the hydraulic distributor upside-down and straight, remove the rubber protection (1), loosen the fastening screws (2) and put the cover down (3). Extract the valve adjustment body (4), then the lock valve (5), the roller (6), the valve seat (7), the spring (8) and the retainer valve (9).

5LA0275

5LA0276

70 5. Remove the discharge valve group with plug (1), sleeve (2), rod (3) and spring (4).

5LA0277

P/N 3681774M1

Edition 01-2006

700-61

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the distributor: - For orientation of parts, refer to the illustration on page 41. - Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Proceed as follows: 1. With all components perfectly clean and lubricated, refit by fastening the distributor body in a vice and reversing the removal sequence. 2. Be very careful to correctly connect the discharge valve (1) into its body (2) with the transversal drainage hole (3) facing the inside of the distributor.

5LA0278

700-62

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT

3. Make sure that all components are correctly positioned, that the control rod (1) and regulator piston (3) in particular are perfectly free and slide in their respective seats for the entire stroke.

5LA0271

5LA0273

74 Hydraulic inspections and adjustments The distributor hydraulic control puts the assembly into the various operating conditions of the power lift. These tests allow the valves to be calibrated, to make sure that there are no leaks and to establish beforehand whether the assembly operates within the limits for which it was designed and built. The following tests can be carried out: - Anti-shock valve inspection and adjustment - Discharge valve leakage inspection - Check valve leakage inspection - Maximum valve inspection and calibration - Delivery pipe leakage inspection Use transmission oil at a temperature of approximately 50Â°C corresponding to a density of 3-3.5 Enghel degrees when performing the off-vehicle hydraulic checks and inspections. Use a high pressure pump (e.g. an injector test hand pump) and specific tool 120 IDR GL which simulates the power lift distributor.

P/N 3681774M1

Edition 01-2006

700-63

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Anti-shock valve inspection and adjustment 1. Position and fasten the distributor assembly (2) inside the tool (1) 120 IDR GL. 2. Connect the high pressure pump pipe (3) to the upper fitting (4) of the tool. 3. Connect between the foot of the tool (1) 120 IDR GL and the distributor rod (5), tool (6) 121 IDR GL or screw and nut which performs the same functions. Loosen the screw to push the distributor rod inwards to take the distributor to discharge step and neutral step. To identify the discharge valve start of closure point, operate the hand pump until oil stops flowing out from the discharge pipe (7). Extend the tool by 1 mm to confer a covering of

the discharge outlet of the discharge valve (8). 4. Operate the pump to open the anti-shock valve (9). This opening must occur at 200 bars. If this fails to occur, adjust the valve by means of the adjustment screw of the spring (10). Tighten the adjustment screw to increase the setting value, slacken it off to decrease the value. 5. After calibrating the valve, hold the pressure in the circuit at a value of approximately 120 bars for 2 or 3 minutes. No oil must leak from the anti-shock valve. If this does not occur, lap the seat with fine emery to ensure a perfect hold.

5LA0279

700-64

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0281

P/N 3681774M1

Edition 01-2006

700-65

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Discharge valve leakage inspection 1. Keep the pump (3) connected to the same union (4) and keep tool (6) 121 IDR GL fitted in the same position as the previous test. 2. Operate the hand pump to take the pressure in the circuit to 100 bars. In these conditions, the pressure must be maintained or drop very slowly. The presence of leakage is manifested by oil being let out through the pipe (7).

The maximum admitted leakage between the piston (8) and its seat (11) is 4 cm3 in 1 minute at a pressure of 100 bars and with oil at approximately 50Â°C. If this value is exceeded, remove the valve and replace the o-rings. Then repeat the test and if the leakage remains, replace the discharge valve (8) and its seat (11).

5LA0279

700-66

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0281

78 Check valve leakage inspection Another cause of leakage may be the check valve (12). To facilitate location and to define the entity of the leakage, remove the maximum valve (13) which is in direct communication with the check valve delivery pipe (12). Oil cannot be let out from the respective pipe directly in this way. If this occurs, lap the seat with fine emery to recreate tightness. Do not attempt to recreate the seats by hitting the balls or the valves because this would only cause stretching and possible oil leakage.

P/N 3681774M1

Edition 01-2006

700-67

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Maximum valve inspection and calibration This test must be performed with tool (1) 120 IDR GL. Move the pump delivery pipe (2) to the lower union (3) and fasten the closing plug on the union (4) used for the previous test. 1. Fit the previously removed maximum valve (13) on the distributor. 2. Extend the tool (5) 121 IDR GL turning it by one turn and a half with respect to the previous

condition to take the distributor to delivery step. 3. Operate the pump and make the maximum valve (13) open. This opening must occur at 180 bars. If you need to adjust the valve, turn the adjustment screw (14) to increase the pressure and loosen it to decrease it.

5LA0280

700-68

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0281

P/N 3681774M1

Edition 01-2006

700-69

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Delivery pipe leakage inspection 1. Keeping the distributor in the previous conditions, operate the pump and take the pressure in the circuit to 120 bars. 2. Check tightness of the valve (13): there must be no oil leakage. If this does not occur, lap with fine emery the seat to provide perfect tightness again.

3. Check tightness of the regulator piston (15). The maximum admitted leakage is 15 cm3 in 1 minute. If oil leaks from pipe (7), this is due to the play between the upper part (6) of the rod (7) and the distributor body. It will not be due to the discharge valve (8) as this has already been checked. The maximum leakage is 10 cm3 in 1 minute.

5LA0280

700-70

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT 1

5LA0281

P/N 3681774M1

Edition 01-2006

700-71

SECTION 700 - HYDRAULIC CIRCUITS – REAR POWER LIFT On-tractor power lift adjustments The on-tractor power lift adjustments must be performed after removing the assembly for overhauling or to test correct operation. Before adjusting, make sure that the two control levers (position and draft) are perfectly coupled on the sector with the two levers fitted on the power lift (1 and 2), to ensure reaching end of stroke position of the power lift and on the control sector. Take note of any differences. The adjustments must be made with the engine running and oil at a temperature of 50°- 60°C Access the distributor though the opening under the driver’s seat. Perform the following adjustments: - Sensitivity adjustment - Position control adjustment - Draft control adjustment

5LA0282

Sensitivity adjustment The purpose of this adjustment is to confer maximum sensitivity to the power lift by correctly positioning the discharge valve. Proceed as follows: 1. Apply to the power lift arms a minimum weight of 100 kg. 2. Start the engine and run it at 1000-1500 rpm. 3. Take the lifting arms to approximately half stroke with the controlled position lever. 4. Loosen the nut (1) and loosen the discharge valve adjustment screw (2) to seek its opening point. This will be denoted by the appearance of a rhythmic swing from the lift links. Slowly fasten the screw (2) until the rhythmic swinging of the arms ends: the discharge valve is closed in this position. Fasten the screw (2) by another one fourth of a turn to cover the valve by approximately 0.3 mm. The valve is now in maximum sensitivity condition. Fasten the nut (1).

5LA0283

700-72

P/N 3681774M1

Edition 01-2006

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Position control adjustment The purpose of the controlled position adjustment is to ensure the intervention of the arm stroke stops by the linkage system using the hydraulic stop of the cylinder piston for safety functions. Proceed as follows: 1. Apply to the power lift arms a minimum weight of 100 kg. 2. Loosen the screw (1) making the lever (2) integral with the position control shaft (3). 3. Fully raise the position control lever (P) to the stop (4) so that the transmission lever (2) goes against the stop (5). The draft control lever (S) must remain down in zero position (lever 6 against stop 7). 4. Maintaining levers (P) and (S) in this position,

with the help of a wrench, turn the position control shaft anticlockwise (3) until the arms stop moving up because the inner hydraulic stroke trips. Since in controlled position, the maximum upward angular range of the arms must not trip the hydraulic stop a certain safety margin must be left. 5. Therefore, turn the shaft (G) anticlockwise to lower the arms by 20-30 mm. 6. After the operation, make the transmission lever (2) held against the stop (5) integral with the shaft (3) tightening the screw (1). To check operation, move the lifting arms up and down a few times, checking that in maximum raised position they always stop in the same point.

5LA0284

P/N 3681774M1

Edition 01-2006

700-73

SECTION 700 - HYDRAULIC CIRCUITS â&#x20AC;&#x201C; REAR POWER LIFT Draft control adjustment The purpose of the controlled draft adjustment is to ensure that the power lift arms raise a little before the end of the draft lever reaches end of stroke on the control sector when the pivoting support is pulled to maximum rear position (negative draft). Proceed as follows: 1. Take the pivoting support to fully retracted position (maximum negative draft) using tool (1) 127 IDR GL or a long lever. 2. Start the engine and take it to approximately 1000 rpm. 3. Take the controlled position lever (P) all down against the stop (2) and slowly raise the draft control lever (S) to the stop (3) on the sector. Stop the lever movement as soon as the arms lift. 4. Check with a gauge the distance between the lever and the stop (3): the correct dimension is

15-20 mm. If the measurement is larger than 15-20 mm, (3.5-4.5 mm between lever (4) and stop F), shorten the linkage (6) fastening the adjustment plate (7). Make it longer otherwise. Before changing the linkage length (6), stop the engine, block the screw (8) and the lock nut (9). 5. After adjusting, check that the dimension of 15-20 mm remains unchanged when the arms start raising. Otherwise, change the linkage adjustment (6). Note: Controlled draft movements are stopped by the internal safety stop.

5LA0285

700-74

P/N 3681774M1

Edition 01-2006

SECTION 800 STEERING SYSTEM

SECTION 800 - STEERING SYSTEM TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF THE HYDROSTATIC STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-3 STEERING CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-4 SECTIONS AND PROSPECTIVE VIEWS . . . . . . . . . . . . . . . . . Operation - neutral position . . . . . . . . . . . . . . . . . . . . Operation - steering position . . . . . . . . . . . . . . . . . . . Manual steering operation (engine stationary) . . . . . . .

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

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

. . . .

. 800-6 . 800-9 800-10 800-11

ORBITROL - OVERHAUL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 800-14

800-2

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM

MAIN SPECIFICATIONS OF THE HYDROSTATIC STEERING System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydrostatic distributor controlled by the steering wheel

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Orbitrol OSPC 80

Pump type . . . . . . . . . . . . . . . . . . . . . . . . . . . .

geared

Pump flow rate . . . . . . . . . . . . . . . . . . . . . . . .

l/ rpm

27.5 (at maximum engine speed)

Maximum operating pressure . . . . . . . . . . . . . . .

(bar)

150 Â± 5

Steering cylinder . . . . . . . . . . . . . . . . . . . . . . . . Cylinder dimensions. . . . . . . . . . . . . . . . . . . . . .

double acting, balanced mm

Steering wheel . . . . . . . . . . . . . . . . . . . . . . . . . Steering wheel diameter . . . . . . . . . . . . . . . . . .

Telescopic, adjustable height and slant mm

Steering wheel turns . . . . . . . . . . . . . . . . . . . . . Minimum turning radius . . . . . . . . . . . . . . . . . . .

P/N 3681774M1

Edition 01-2006

35 x 57 x204/2

360 2 (right) 1.75 (left)

(m)

2.91 (with brakes) 3.67 (without brakes)

800-3

SECTION 800 - STEERING SYSTEM

800-4

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM

5LA0214

1 Steering circuit

P/N 3681774M1

Edition 01-2006

800-5

SECTION 800 - STEERING SYSTEM

SECTIONS AND PROSPECTIVE VIEWS 1

5LA0313

2 ORBITROL distributor section

800-6

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Check valve One-way valve Stator Rotor Screw Spacer Screw Seal Closing plate O-ring O-ring Distributor plate O-ring Connection shaft Drum

P/N 3681774M1

Edition 01-2006

16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29.

Ring Washer Anti-shock valve Roller bearing Washer O-ring Ring Centring springs O-ring "Orbitrol" distributor Pin Sleeve Anti-cavitation valve Safety valve

800-7

SECTION 800 - STEERING SYSTEM 1

5LA0317

ORBITROL distributor prospective view 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

800-8

Check valve One-way valve Stator Rotor Screw Spacer Screw Seal Closing plate O-ring O-ring Distributor plate O-ring Connection shaft Drum

16. Ring 17. Washer 18. Anti-shock valve 19. Roller bearing 20. Washer 21. O-ring 22. Ring 23. Centring springs 24. O-ring 25. "Orbitrol" distributor 26. Pin 27. Sleeve 28. Anti-cavitation valve 29. Safety valve

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM Operation - neutral position In this position, the drum (1) is centred with respect to the sleeve (2) by the springs. Pipes P1-L-R are not supplied. The oil from the pipe P passes directly to the pipe T to feed the hydraulic unit. The circuit is of the open centre type. Two anti-shock valves (3) and two anti-cavitation valves (4) are placed in the holes L and R of the

distributor. The anti-shock valves (3) protect the circuit between the steering cylinder and the distributor from shocks on the wheels. The anti-cavitation valves (4) let the oil discharged from the anti-shock valves (3) to cross from the right pipe to the left pipe and vice versa, according to the shift of the piston in the steering cylinder. 1

5LA0318

4 A. B. L. P.

Steering cylinder Steering column position Feed to left union of steering cylinder Low flow rate feed from hydraulic pump

P/N 3681774M1

Edition 01-2006

P1. Feed to metering device R. Feed to right union of steering cylinder T. Discharge to hydraulic unit

800-9

SECTION 800 - STEERING SYSTEM Operation - steering position Turning the steering wheel (to the right or to the left) causes an angular rotation of the drum (1) with respect to the sleeve (2). The flow from the pump is conveyed to the metering device, namely the stator (4) and the rotor (3). The rotor (3) turns and sends back to the cylinder a quantity of oil proportional to the rotation angle. The rotation of the rotor (3) is equal to that of the steering wheel. Example: Supposing that the steering wheel is turned by an angle of 5°. This causes an angular rotation of the drum (1) of 5° with respect to the sleeve (2). The rotor (3) is turned until it is fed. It in turn drives the connection shaft and the sleeve (2). When these have turned by 5°, the drum (1) and the sleeve (2) are centred on the springs again. The rotor ceases to be powered and is blocked. The same principle applies to wider angles. The amount of oil discharged by the power steering to the cylinder A is

therefore proportional to the rotation angle of the steering wheel. The drum (1) allows according to whether steering to the left or right to send oil from the metering device - stator (4) and rotor (3) - to the hole L or R. The sleeve (2) ensures during the rotation the synchronous communication of the metering device cavities with the circuit form the pump on one side and the circuit to the cylinder A on the other. A check valve (5) is fastened into the distributor feed hole. This is a one-way valve which prevents excessive pressures exerted on the wheels to be transmitted to the pump when the wheels are steered. If the pressure in the steering circuit is too high, the safety valve (6) located on the distributor is stressed and the pressure in excess is directed towards the pipe T.

5LA0319

5 A. B. L. P.

800-10

Steering cylinder Steering column position Feed to left union of steering cylinder Low flow rate feed from hydraulic pump

P1. Feed to metering device R. Feed to right union of steering cylinder T. Discharge to hydraulic unit

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM Manual steering operation (engine stationary) The rotor (2) is not hydraulically driven when the pump is not conveying oil and when the available pressure is too low. There is no power assistance in this case. Turning the steering wheel will compress the centring springs. This cancels the angular float between the pin and the sleeve and the rotor is driven mechanically. The distributor now works as a

manual pump. The return oil from the cylinder A crosses the check valve (3) and supplies the metering device. The pressure generated is proportional to the torque exerted on the steering wheel. In this case, the effort on the steering wheel is high.

5LA0320

6 A. B. L. P.

Steering cylinder Steering column position Feed to left union of steering cylinder Low flow rate feed from hydraulic pump

P/N 3681774M1

Edition 01-2006

P1. Feed to metering device R. Feed to right union of steering cylinder T. Discharge to hydraulic unit

800-11

SECTION 800 - STEERING SYSTEM

ORBITROL - OVERHAUL Disassembly WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Proceed as follows: 1. Remove the distributor from the tractor. 2. Fasten the distributor to the vice. Close the vice so to avoid damage. 3. Loosen the screws (1) and (5) and mark their respective position. 4. Remove the closing plate (9), the o-ring (10), the stator (3) and the o-ring (11). 5. Remove the spacer (6), the rotor (4), the distributor plate (12) and the o-ring (13). 6. Extract the spline shaft (14). 7. Remove the threaded bushing and recover the check valve ball (2). 8. Extract the two spring pins and two balls from the anti-cavitation valves (28) of the distributor. 9. Extract by pushing the sleeve unit (27) and drum (15), checking that the pin (26) is directed on the horizontal axis. 10. Remove the washers (17) and (20), the roller bearing (19) and the bushing (16) from the sleeve/drum assembly. Remove the pin (26) and the centring springs (23) by pushing on one of the ends. Separate the sleeve (27) from the drum (15). 11. Remove the safety valve plug (29). With a 8 mm Allen wrench, remove the threaded bushing and remove the seal, the spring and the valve (the recessed seat cannot be removed). 12. Loosen the two anti-shock valves (18) and remove the seals. With a 6 mm Allen wrench, remove the threaded bushing and remove the springs, the balls and the seats (the recessed seats cannot be removed). 13. Extract the o-ring (24), the bushing (22) and the o-ring (21). 14. Remove the check valve (1).

800-12

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM 1

5LA0313

P/N 3681774M1

Edition 01-2006

800-13

SECTION 800 - STEERING SYSTEM Assembly

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear.

Comply with the following recommendations when refitting the Orbitrol distributor: - For orientation of parts, refer to the illustration on pages 6 and 7. - Apply the tightening torques listed on page 100.

Carefully clean all parts and inspect them.

Replace all o-rings.

Replace all damaged or worn components.

Check rolling tracks of all bearings for anomalies while rolling.

Lubricate with grease the bearing and o-ring seats.

Check with a jet of air for obstructions of the channels and lubrication oil passage holes.

Proceed as follows: 1. Remove the check valve (1, fig. 7). 2. Fit the o-ring (24, fig. 7). 3. Fit the o-ring (21) and the ring (22) on the tool (115 IDR GL). 4. Position the complete tool in the distributor body (5) and push the tool until the o-rings are fitted in their seats.

5LA0321

800-14

P/N 3681774M1

Edition 01-2006

SECTION 800 - STEERING SYSTEM 5. Arrange the balls and springs in the anti-shock valve seats (18, fig. 7). Fasten the threaded bushings, arrange the seals and tighten the plugs. 6. Arrange the valve and the spring in the discharge valve (29, fig. 7) and fasten the threaded bushing. Arrange the seal and fasten the plug at a torque of 40 - 60 Nm. 7. Insert the drum (5, fig. 7) in the sleeve (27, fig. 7).

8. Introduce the tool 113 IDR GL for fitting the centring springs (23) through the slot. Fasten the springs on the tool as shown and arrange the pin (26, fig. 7).

5LA0322

5LA0323

10 9. Position the bushing (16, fig. 7) on the sleeve and drum assembly using the chamfering to facilitate assembly in the distributor. 10. Arrange the washers (17 and 20, fig. 7), with the washer chamfering (17, fig. 7) oriented towards the centring springs (23, fig. 7) placing the roller bearing in between (19, fig. 7). 11. Fit the sleeve and drum assembly in the distributor applying a slight oscillating movement. Make sure that the pin (26, fig. 7) is held horizontally. 12. Arrange the two balls and the two spring pins in the suction valve seat (28, fig. 7). 13. Arrange the ball in the check valve seat (2, fig. 7) and fasten the threaded bushing.

P/N 3681774M1

Edition 01-2006

800-15

SECTION 800 - STEERING SYSTEM 14. Extract the connection spline shaft (14, fig. 7). 15. Arrange the o-ring (3, fig. 7) and the distributor plate (12, fig. 7). 16. Fit the rotor (4) so that the two C cavities are in line with the spline shaft axis (14). Refit the spacer 6, fig. 7).

5LA0324

11 17. Arrange the o-rings (10, fig. 7) and (11, fig. 7) on the stator (3, fig. 7). 18. Avoid moving the rotor (4, fig. 7) and refit the stator (3, fig. 7). Then move the stator so that its fastening holes correspond to that of the distributor. The rotor (4) and the slot C must be in the position shown.

5LA0325

12 19. Refit the closing plate (9, fig. 7). 20. Refit the screw (5, fig. 7) in the position marked during disassembly and the screws (7, fig. 7) with seals (8, fig. 7). Tighten crossingly at a torque of 30-35 Nm. 21. Use an appropriate pad to check settings and operation of the distributor. 22. Refit the distributor on the tractor.

800-16

P/N 3681774M1

Edition 01-2006

SECTION 900 BRAKES

SECTION 900 - BRAKES TABLE OF CONTENTS Description

Page

MAIN SPECIFICATIONS OF BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-4 CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-5 SECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-6 ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-8 Rear brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-8 Front brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-9 Parking brake adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 900-10

900-2

P/N 3681774M1

Edition 01-2006

SECTION 900 - BRAKES

MAIN SPECIFICATIONS OF BRAKES Rear brakes Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wet multiple disc fitted on rear differential axle shafts

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IBS hydraulic (simultaneous braking with front brakes) operated by two pedals positioned on the driverâ&#x20AC;&#x2122;s right.

Nr. of friction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8 (4 per side)

Friction material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

resin-graphite

Front brakes Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wet multiple disc fitted on rear differential axle shafts

Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

IBS hydraulic (simultaneous braking with rear brakes) operated by two pedals positioned on the driverâ&#x20AC;&#x2122;s right.

Nr. of friction plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 (2 per side)

Friction material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

resin-graphite

Parking brake Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hand lever and independent linkages acting directly on service brakes

Trailer brake (optional) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

P/N 3681774M1

Edition 01-2006

hydraulic

900-3

SECTION 900 - BRAKES

DESCRIPTION AND OPERATION The tractor braking system is characterised by an â&#x20AC;&#x153;IBSâ&#x20AC;? (Integral Braking System) featuring a hydrostatic control circuit and front and rear wet discs. Braking is governed by a control valve which determines the operation of either only the rear brakes or the front and rear brakes at the same time.

The control valve ensures braking on the four wheels when the pedals are coupled by means of a bolt and on the rear wheels only when only one pedal is pressed or when the pedals are not bolted together.

5LA0326

1 1. Brake cylinders 2. Check valve 3. Front disk brakes

900-4

4. Rear disk brakes 5. Hydraulic trailer brake (optional)

P/N 3681774M1

Edition 01-2006

SECTION 900 - BRAKES

CONTROLS 1

1 3 2

5LA0327

2 Brake controls 1. Left brake control pedal 2. Right brake control pedal

P/N 3681774M1

Edition 01-2006

3. Coupling bolt 4. Parking brake control lever

900-5

SECTION 900 - BRAKES

SECTIONS 1

5LA0328

Rear differential - rear brakes cross-section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

900-6

Differential lock rod Spring Differential lock fork Differential lock hydraulic actuator Supporting flange Adjuster shim AXLE SHAFT Taper bearing Slewing bearing Planetary gear

11. Satellite gear 12. Satellite pin 13. Slewing bearing 14. Differential housing 15. Taper bearing 16. AXLE SHAFT 17. Adjuster shim 18. Supporting flange 19. BRAKE ASSEMBLY

P/N 3681774M1

Edition 01-2006

SECTION 900 - BRAKES

5LA0286

Front differential - front brakes cross-section 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

LEFT AXLE SHAFT Screw BRAKE CASING COVER Ring nut Piston Brake housing Taper bearing Satellite pin Screw Ring nut LOCK CASING O-ring O-ring PISTON DISC BRAKE COUNTER DISC HYDROLOCK CASING Spring guide O-ring Thrust slewing bearing RIGHT AXLE SHAFT Snap ring

P/N 3681774M1

Edition 01-2006

23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. 41. 42. 43.

Slewing bearing O-ring Piston O-ring Union Cap Spring Snap ring BRAKE HUB Bevel pinion ring Bevel pinion O-RING TAPERED BEARING Shim Taper bearing Bevel ring gear Differential mount Snap ring Brake hub Axial guard Planetary gear

900-7

SECTION 900 - BRAKES

ADJUSTMENTS Rear brake adjustment WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. This adjustment is required whenever the control panel free stroke is excessive and the pedals are near end of stroke. Make sure that the control pedal free stroke is approximately 35 mm.

Proceed as follows: Make sure that there is no air in the hydraulic brake circuit. Otherwise, bleed the circuit as shown in the general service procedure section. Air is normally present when the pedal feels spongy. 1. Lift the rear wheels with a jack. 2. Make sure that the parking brake is not engaged. 3. Make the two brake pedals independent by lifting the coupling bolt. 4. Loosen the lock nut (1). Fasten the nut (2) slowly until the wheel cannot be turned by hand anymore.

5LA0329

900-8

P/N 3681774M1

Edition 01-2006

SECTION 900 - BRAKES 5. Mark a reference line on the nut (2) and on the control lever (3).

5LA0329

6 6. Loosen the adjustment nut (2) by one turn and 1/6th and until the wheel can be turned again by hand. Fasten the lock nut.

5LA0330

7 7. Check that the pedal free stroke is approximately 35 mm. Otherwise, repeat the adjustment procedure.

5LA0331

8 8. Repeat the same operations on the other side, making sure that the brake pedal free stroke is identical and that they work simultaneously.

Front brake adjustment No periodical adjustment is needed because these brakes are self-adjusting.

P/N 3681774M1

Edition 01-2006

900-9

SECTION 900 - BRAKES Parking brake adjustment WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and the next. Wear approved safety garments such as goggles, gloves and safety footwear. Make sure that the parking brake lever is operated after two notches felt on the button on the lever itself.

Proceed as follows: Adjust the brakes as shown in the procedure on page 8.

1. Adjust the lever idle stroke by means of the adjustment nut (1) until the brake is applied at the second notch of the stroke.

1 5LA0332

900-10

P/N 3681774M1

Edition 01-2006

SECTION 1000 ELECTRICAL SYSTEM - INSTRUMENTS

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS TABLE OF CONTENTS Description

Page

INSTRUMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warning light identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Indicators and external connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . RPM meter and hour counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel level gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine coolant temperature indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TRANSMITTERS, SENSORS AND SOLENOID VALVES

1000-3 1000-4 1000-5 1000-7 1000-7 1000-7

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-8

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-12 Instrument replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1000-12

1000-2

P/N 3681774M1

Edition 01-2006

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

INSTRUMENTS

10 P

STOP

rpm

0 1

x 100

ECO

2 FRONT

B Km/ha MPH

4LA0006

1 The instrument is positioned on the dashboard. It consists of nine display sections, plus two side selection and programming buttons. 1. 2. 3. 4. 5. 6. 7. 8.

On/off and warning lights RPM meter and hour counter On/off and warning lights Fuel level gauge Right turn indicator warning light PTO speed digital display Tractor speed digital display Left turn indicator warning light

P/N 3681774M1

Edition 01-2006

9. Engine coolant temperature instrument A-B.Programming/setting buttons for the following functions: - Clock - Odometer - PTO speed - Hour counter reset - Worked area

1000-3

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS Warning light identification

2 3

7 8

10 P

STOP

rpm

x 100

ECO

2 FRONT

N 6

18 Km/ha MPH

4LA0011

2 The position of indicator lights on the panel and their functions are described in the following list: FUNCTION

INDICATOR COLOUR

1. ALTERNATOR

red

2. ENGINE OIL PRESSURE

red red

3. HANDBRAKE

yellow

4. SUPER FINAL DRIVE

blue

5. DRIVING BEAM HEADLIGHTS

green

6. SIDE LIGHTS

red

7. TRAILER BRAKE OIL PRESSURE 8. ENGINE ALARM

yellow

9. DIFFERENTIAL LOCKS

yellow

10. TRAILER FIRST TURN INDICATOR

green

11. 4WD ENGAGED

yellow

12. TRAILER SECOND TURN INDICATOR

green red

13. OBSTRUCTED AIR CLEANER 14. HYDRAULIC CIRCUIT VACUUM METER

red

15. TRANSMISSION OIL FILTER

red

16. PTO OVERSPEED (NAO MARKET)

yellow

17. SYNCHRONISED PTO

yellow

18. FRONT PTO

yellow red

19. BRAKE OIL PRESSURE

1000-4

P/N 3681774M1

Edition 01-2006

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

FUNCTION

INDICATOR COLOUR

20. GLOW PLUGS

yellow

21. ECO PTO

yellow

22. MID/BY SPEED PTO

yellow

23. REAR PTO (INDEPENDENT PTO)

yellow

24. FAST PTO / WHEEL SLIP

yellow

25. FORWARD DIRECTION

green

26. REVERSE DIRECTION

green red

27. BRAKES 28. COOLANT TEMPERATURE

red

29. FUEL RESERVE

yellow

30. RH DIRECTION

green

31. LH DIRECTION

green

Indicators and external connections Refer to the following table to identify the indicators on the panel: FUNCTION BATTERY HANDBRAKE ENGINE OIL PRESSURE BRAKE OIL PRESSURE Not connected HYDRAULIC CIRCUIT VACUUM METER OBSTRUCTED AIR CLEANER KEY (IGNITION) TRANSMISSION OIL FILTER 4WD ENGAGED DIFFERENTIAL LOCKS SUPER FINAL DRIVE MID/BY SPEED PTO GROUND SYNCHRONISED PTO REAR PTO (INDEPENDENT PTO) FRONT PTO ECO PTO TRAILER BRAKE OIL PRESSURE ENABLE SLIP CONTROL DRIVING BEAM HEADLIGHTS SIDE LIGHTS LH DIRECTION RH DIRECTION TRAILER FIRST TURN INDICATOR TRAILER SECOND TURN INDICATOR

P/N 3681774M1

Edition 01-2006

CONNECTOR A PIN N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

1000-5

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

FUNCTION ENGINE RPM REAR PTO RPM SPEED CAN_SHIELD CAN_H CAN_L BATTERY RADAR BUZZER ALTERNATOR (D+) K LINE (SERIAL) REVERSE DIRECTION KEY (IGNITION) FUEL RESERVE SLOW PTO FAST PTO GLOW PLUGS FORWARD DIRECTION GROUND Not connected COOLANT TEMPERATURE FUEL LEVEL Not connected Not connected Not connected Not connected

1000-6

CONNECTOR B PIN N. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26

P/N 3681774M1

Edition 01-2006

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS RPM meter and hour counter Engine RPM is shown on an analogue gauge on which, as RPM increases, a pointer moves around a graduated scale. The indication must be multiplied one hundred. The LCD inside the instrument provides the following indications: - clock function - hour counter function (resettable) - worked area function - engaged gears function.

STOP

rpm

x 100

N 4LA0041

3 Fuel level gauge Indicates the level of the fuel in the tank. The pointer moves fully towards the right when the tank is full (green zone). When the fuel tank is less than ¼ full, the pointer moves to the yellow zone and the indicator (1) lights up to indicate fuel reserve conditions.

4LA0042

4 Engine coolant temperature indicator - Blue zone = low temperature (engine cold) - Green zone = temperature OK - Red zone = engine excessively overheated. In this latter case, the engine must be allowed to idle (without being stopped). Check the cooling system if the indication persists. Indicator light (1) on the instrument comes on when the temperature reaches 105−110°C.

4LA0043

P/N 3681774M1

Edition 01-2006

1000-7

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

TRANSMITTERS, SENSORS AND SOLENOID VALVES

D E

4LA0035

1000-8

P/N 3681774M1

Edition 01-2006

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

TRANSMITTERS, SENSORS AND SOLENOID VALVES

4LA0038

P/N 3681774M1

Edition 01-2006

1000-9

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

TRANSMITTERS, SENSORS AND SOLENOID VALVES

L I

O P

4LA0039

1000-10

P/N 3681774M1

Edition 01-2006

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

TRANSMITTERS, SENSORS AND SOLENOID VALVES A. ENGINE COOLANT TEMPERATURE SENSOR (for starter) Detects the maximum engine coolant temperature limit. B. ENGINE COOLANT TEMPERATURE SENSOR (for instrument panel) The resistance of the temperature transmitter varies in proportion to the temperature of the coolant, generating a modulated voltage that is measured by the instrument. C. ALTERNATOR Transmits a square wave signal, recharges the battery and makes up for the power draw depending on the amount required by the users. D. ENGINE OIL PRESSURE SENSOR. Operates as soon as the pressure of the engine oil drops below a certain value, after which the indicator light on the instrument comes on. E

HYDRAULIC OIL PUMP OBSTRUCTION PRESSURE SWITCH Detects the pressure difference in the hydraulic circuit and lights up the indicator on the instrument panel if an obstruction is found.

BRAKE FLUID LEVEL SENSOR Detects the level of brake fluid in the tank inside the dashboard (right-hand side) and lights up the respective indicators on the instrument panel.

FUEL PUMP This is fastened to the fuel filter and is connected in parallel to the injection pump and the starter.

GEARBOX OIL VACUUM METER Detects the pressure difference in the gearbox oil circuit and lights up the respective indicator if the pressure is low.

4WD SOLENOID VALVE Controls hydraulic operation of 4WD and is connected to the respective switch on the right mudguard.

BY SPEED SOLENOID VALVE Controls the by speed system hydraulic circuit.

M REAR PTO SOLENOID VALVE AND PTO BRAKE Controls the rear PTO hydraulic circuit and is connected to the respective control switch on the right mudguard. N

AIR CLEANER VACUUM METER Comes into action when the vacuum in the air suction system exceeds a predetermined value and lights up the indicator on the instrument panel.

O FUEL LEVEL TRANSMITTER The signal issued by the transmitter determines the fuel level indicated on the instrument and turns on the warning light when the fuel is in reserve. P

DIFFERENTIAL LOCK SOLENOID VALVE Controls the differential lock circuit by means of the respective button on the right mudguard.

SPEED SHIFT SOLENOID VALVE Controls operation of the gear shift hydraulic circuit and is connected to the control button on the gear lever.

P/N 3681774M1

Edition 01-2006

1000-11

SECTION 1000 - ELECTRICAL SYSTEM - INSTRUMENTS

MAINTENANCE Instrument replacement Proceed as follows to replace the instrument: 1. Use a screwdriver as a lever in order to remove the instrument from its housing.

10 P

STOP

rpm

0 1

x 100

ECO

FRONT

Km/ha MPH

4LA0058

9 2. Remove the instrument from its housing and disconnect the connectors (1) and (2). 3. Fit a new instrument and reconnect the two connectors, considering that they are not interchangeable despite the same number of pins and the same shape. Indeed, connector (1) has five inner references (keys) while connector (2) has three.

4LA0013

1000-12

P/N 3681774M1

Edition 01-2006

SECTION 1010 ELECTRICAL SYSTEM - COMPONENTS

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS TABLE OF CONTENTS Description

Page

CONTROL PANEL WITH ANALOGUE/DIGITAL INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-3 HAZARD LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4 ROTATING LIGHT SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4 IGNITION SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-4 LIGHT STALK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Turn indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving beam blinking function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Side and tail lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Driving/dipped beams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Horn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1010-5 1010-5 1010-5 1010-6 1010-6 1010-6

WORKING LIGHT SWITCH (VERSION WITHOUT CAB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-6 RIGHT SIDE COMMANDS (VERSION WITHOUT ELECTRONIC POWER LIFT) . . . . . . . . . . . . . . . . . Differential lock button (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4WD and by speed switch (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTO switch (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Speed shift button (2, fig. 9) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1010-7 1010-7 1010-8 1010-8 1010-8

RIGHT SIDE COMMANDS (VERSION WITH ELECTRONIC POWER LIFT) . . . . . . . . . . . . . . . . . . . . . 1010-9 Differential lock button (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-9 4WD and by speed switch (2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-9 PTO switch (3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-10 Electronic power lift control panel (4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-10 External controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-11 CONTROLS ON THE RIGHT CAB PILLAR A/C knob (1) . . . . . . . . . . . . . . Fan knob (2) . . . . . . . . . . . . . . A/C button (3) . . . . . . . . . . . . . Front working light switch (4) . . Washer switch (5) . . . . . . . . . . Rear working light switch (6) . . .

. . . . . . .

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

. . . . . . .

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

. . . . . . .

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

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

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

1010-12 1010-12 1010-12 1010-13 1010-13 1010-13 1010-13

CAB COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-14 ISO/NAO REAR LIGHTS . . . . . . 1. ISO version . . . . . . . . 2. NAO version . . . . . . . . Reverse light (Japan only)

. . . .

1010-15 1010-15 1010-15 1010-15

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headlight bulbs. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Front side light and turn indicator bulbs. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . Tail light, brake light and rear turn indicator bulbs. Replacement . . . . . . . . . . . . . . . . . . . Cab working light bulbs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rear working light bulb (version without cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rotating light bulb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1010-16 1010-16 1010-17 1010-17 1010-18 1010-18 1010-19

BULB SPECIFICATIONS OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1010-19

1010-2

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

CONTROL PANEL WITH ANALOGUE/DIGITAL INSTRUMENT

4LA0005

1 1. Central analogue/digital instrument 2. Hazard light switch 3. Rotating light switch

P/N 3681774M1

Edition 01-2006

4. Ignition switch 5. Light switch 6. Working light switch (version without cab only)

1010-3

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

HAZARD LIGHT SWITCH Press the switch (2, fig. 1) to turn on the hazard lights. After the button has been pressed, the switch will blink along with the turn indicators.

ROTATING LIGHT SWITCH Press the switch (3, fig. 1) to operate the rotating light.

4LA0000

IGNITION SWITCH Turn the key to the following positions to obtain the three ignition switch functions (4, fig. 1): - position A = no circuit powered (the key can be removed). The engine stops. - position B = presetting position for engine ignition. The indicator lights and monitoring instruments light up. Various users are powered. - position C = the thermo starter warms up so that the engine can start in cold climates. - position D = cranks the engine: the key returns automatically to position (B) when released. 2LA0710

1010-4

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

LIGHT STALK The light stalk (1, fig. 4) is arranged near the steering column and operates: turn indicators, headlight blinks, side/taillight, dipped beam and driving headlight selection, horn. Turn indicators To signal that you are about to turn to the left, pull the light switch lever (1) back to position (C). To signal that you are about to turn to the right, push the lever forwards to position (D).

2LA0485

4 Driving beam blinking function With the lights off or with the driving beams on, push the lever up to position (A, fig. 4) to blink the driving beams. The lever will automatically return to its original position when released.

P/N 3681774M1

Edition 01-2006

1010-5

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS Side and tail lights Turn knob (3) taking pointer (2) to symbol (1). The side and tail lights and the control panel will light up.

2LA0486

5 Driving/dipped beams Move the pointer (2) of the knob (1) to symbol (3) to turn on the dipped beams or down to position (B, fig. 4) for the fixed driving beams. Horn Press the button at the end of the lever (1, fig. 4) to operate the horn.

2LA0487

WORKING LIGHT SWITCH (VERSION WITHOUT CAB) To operate the rear working light (1), press the switch (6, fig. 1) on the left of the control panel.

4LA0007

1010-6

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

RIGHT SIDE COMMANDS (VERSION WITHOUT ELECTRONIC POWER LIFT)

4LA0004

8 The following controls and components are located on the right mudguard: 1. Differential lock button 2. 4WD and by speed switch

3. PTO switch 4. Cigar lighter

Differential lock button (1) Press button (1) to lock the differential. Locking is confirmed by the indicator light (9, fig. 2) described in section 1000. Depress one or both of the brake pedals to unlock the differential. To obtain the best result, the diff lock should be engaged before the wheels begin to slip. Do not engage the lock while a wheel is actually slipping.

P/N 3681774M1

Edition 01-2006

1010-7

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS 4WD and by speed switch (2) This control engages 4WD and switch position of the by speed function controlled by the lever (1, fig. 6). PTO switch (3) The switch (3, fig. 8) is used to switch the PTO on and off. - on = switch turned towards the cab window - off = switch turned N position PTO engagement is managed by an electromagnetic clutch. The respective indicator lights up on the instrument panel when engaged.

Speed shift button (2, fig. 9) Press the button (2), positioned on the gearbox lever (1), to engage the speed shift system (for shift down by half a gear). The button controls via a toggle relay and relay switch the solenoid valve of the hydraulic system related to the system.

4LA0051

1010-8

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

RIGHT SIDE COMMANDS (VERSION WITH ELECTRONIC POWER LIFT)

P STO

N 1

4 5LA0364

10 1. Differential lock button 2. 4WD and by speed switch

3. PTO switch 4. Electronic power lift control panel

4WD and by speed switch (2) This control engages 4WD and switch position of the by speed function controlled by the lever (1, fig. 6).

P/N 3681774M1

Edition 01-2006

1010-9

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS PTO switch (3) The switch (3, fig. 8) is used to switch the PTO on and off. - on = switch turned towards the cab window - off = switch turned N position

PTO engagement is managed by an electromagnetic clutch. The respective indicator lights up on the instrument panel when engaged.

Electronic power lift control panel (4) This is located on the right mudguard and controls the entire system.

C B A

7 4LA0131

11 1. Three position up/down switch: A. Down - Working position. Working position is obtained according to the setting of controls (6 and 8) B. Stop - No power lift arm movements are allowed in this position C. Up - Transport: the maximum lift position is determined by the limiter (4) 2. Descent speed selector: 0 - No descent. Padlock - Turned anticlockwise 3. Electronic power lift “Check Control” self-diagnostic indicator 4. Maximum height limiter: Minimum height, turned anticlockwise Maximum height, turned clockwise

1010-10

5. Lifting indicator 6. Function selector: Position control, turned anticlockwise Draft control, turned clockwise Intermediate positions: draft and position control combination (INTERMIX) 7. Lowering indicator 8. Implement working depth/height control 0 - Down 10 - Max. height from ground 9. “Shock Absorber” button and indicator in transport position 10. Quick dig button

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS External controls The power lift can be controlled by two outer buttons positioned respectively on two rear sides of the tractor, by the side of the rear lights: 1. Arm up button 2. Arm down button

4LA0132

12 The entire electronic power lift system is controlled by an electronic unit wired into the right mudguard. See section 1050, page 48 for a specific description of this unit.

P/N 3681774M1

Edition 01-2006

1010-11

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

CONTROLS ON THE RIGHT CAB PILLAR The following controls are fitted on the right cab pillar: 1. 2. 3. 4. 5. 6.

A/C knob Fan knob A/C button Front working light switch Washer switch Rear working light switch

1 2

1 0

3 4 5 6

4LA0008

13 A/C knob (1) Turn the knob anticlockwise (to the blue zone) for maximum cooling. Turn the knob clockwise for maximum heating. Fan knob (2) The fan works with the ignition key in position B (see fig. 3) and has four working positions: 0. Stop 1. Low speed 2. Medium speed 3. High speed

1010-12

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS A/C button (3) This controls the A/C compressor (1) and is enabled when the engine is running.

4LA0021

14 Front working light switch (4) This switches on the front working lights on the cab roof.

Washer switch (5) This control has a neutral central position and two unstable side positions: press leftwards to operate the windscreen washer pump. Press rightwards to operate the rear window washer. Press the switch (1) located directly on the front windscreen to operate the windscreen wiper motor.

4LA0019

15 Press the switch (1) located directly on the front window to operate the rear window wiper motor.

4LA0020

16 Rear working light switch (6) This switches on the rear working lights on the cab roof.

P/N 3681774M1

Edition 01-2006

1010-13

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

CAB COMPONENTS

4LA0015

17 The following components are arranged under the cab roof: 1. Ceiling light 2. Left radio speaker

1010-14

3. Right speaker

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

ISO/NAO REAR LIGHTS The rear light clusters differ in terms of functions and components according to version type. Two versions are available: 1. ISO version - light cluster with brake light and tail light function (2) (red lens), turn indicators (1) (yellow lens); - a light cluster (3) with supplementary brake light and tail light (red lens).

4LA0009

18 2. NAO version - a light cluster (1) with turn indicator functions (yellow lens) - a light cluster (2) with supplementary tail light and turn indicators (red lens).

4LA0012

19 Reverse light (Japan only) A reverse light is provided for the Japanese market. The light is white and combined with a buzzer for indicating tractor movements.

P/N 3681774M1

Edition 01-2006

1010-15

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

MAINTENANCE Headlight bulbs. Replacement CAUTION Handle halogen bulbs by the metal part only. The light intensity of the bulb would be impaired if it were touched by the fingers and it would not last so long. If your fingers accidentally touch the bulbs, clean them with a cloth soaked in cleaning spirits and allow them to dry. Proceed in the following way to replace the burntout bulbs: - pull the red knob (1) on the engine (right hand side) and then lift the engine bonnet;

4LA0026

20 -

detach the connection (3) on the headlight (1); remove the rubber guard (2); release the spring that holds the light fitting in place and turn in an anticlockwise direction remove the bulb. Replace the halogen lamp with a new one with the same rating (55รท60 W).

1 4LA0025

1010-16

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS Front side light and turn indicator bulbs. Replacement Remove the transparent cover (3), and replace the faulty lamp with a new one with the same rating: - turn indicator bulb (1) (21W): press the bulb inwards, turn it in the anti-clockwise direction and remove it; - turn indicator bulb (2) (21W): pull the bulb outwards and replace it. The orange lens must be fitted back pointing upwards. 2LA0495

22 Tail light, brake light and rear turn indicator bulbs. Replacement Remove the transparent cover (1), press the burntout bulb inwards, turn it in the anti-clockwise direction and remove it. Replace it with another of an equal power rating: - turn indicator bulb (21W): - double-filament brake lights and side lights 21W/5W.

The orange lens must be fitted back pointing downwards. 4LA0057

23 CAUTION Handle halogen bulbs by the metal part only. The light intensity of the bulb would be impaired if it were touched by the fingers and it would not last so long. If your fingers accidentally touch the bulbs, clean them with a cloth soaked in cleaning spirits and allow them to dry.

P/N 3681774M1

Edition 01-2006

1010-17

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS Cab working light bulbs Proceed as follows to replace the working light bulbs: - turn the headlight (1) to reach the rear part (wire inlet side); - turn the bulb holder connection unit (2) and extract it from the headlight; - Remove the halogen bulb and replace the burnt-out bulb with another of an equal power rating (55 W).

4LA0018

2 24

Rear working light bulb (version without cab) Proceed in the following way to replace the bulb: - loosen the four lens fastening screws (1);

4LA0016

25 -

open the tab (1) and extract the bulb holder (2); replace the burnt-out bulb with another of an equal power rating (40 W).

2 4LA0017

1010-18

P/N 3681774M1

Edition 01-2006

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS Rotating light bulb To replace the rotating light bulb, loosen the orange lens, then extract the bulb (1) from the holder and replace it with one of equal rating (55 W).

4LA0023

BULB SPECIFICATIONS OVERVIEW

BULB FUNCTION DRIVING BEAM HEADLIGHTS DIPPED BEAM HEADLIGHTS NUMBER PLATE LIGHT TURN INDICATORS SIDE/TAIL LIGHTS BRAKE LIGHTS REVERSE LIGHT (Japan version) ROTATING LIGHT CAB CEILING LIGHT WORKING LIGHTS (with cab) WORKING LIGHT (version with cab)

P/N 3681774M1

Edition 01-2006

POWER 60 W 55 W 5W 21 W 5W 21 W 21 W 55 W 10 W 55 W 40 W

TYPE OF ATTACHMENT

TYPE OF BULB

H4 H4

halogen halogen filament filament filament filament filament halogen filament halogen halogen

H1 H3

1010-19

SECTION 1010 - ELECTRICAL SYSTEM - COMPONENTS

1010-20

P/N 3681774M1

Edition 01-2006

SECTION 1020 ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM TABLE OF CONTENTS Description

Page

TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-4 TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition system test on the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power draw in the starter motor circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Resistance in the ignition system circuit (voltage drop) . . . . . . . . . . . . . . . . . . . . . . . . . . . Positive battery cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ground connection of the starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery ground cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1020-5 1020-5 1020-5 1020-6 1020-6 1020-6 1020-7

STARTER MOTOR. REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1020-7

1020-2

P/N 3681774M1

Edition 01-2006

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM

TECHNICAL SPECIFICATIONS FEATURES

TYPE OF STARTER MOTOR

Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . .

PERKINS 32A66-11100,4318 - 12V

Power rating . . . . . . . . . . . . . . . . . . . . . . . . (kW)

2.2

Maximum power draw with no load (A) . . . . . . . .

60 at 11.7 V and 7000 RPM

Spinning direction (viewed from pinion side) . . . .

clockwise

Minimum diameter of commutator . . . . . . . (mm)

Maximum armature shaft float . . . . . . . . . . (mm)

0.1 - 0.4

P/N 3681774M1

Edition 01-2006

1020-3

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM

DESCRIPTION AND OPERATION The type of ignition system depends on the type of gearbox mounted on the tractor. All systems include a key-switch, starter motor with electromagnet, switches for the gearbox, reduction gear on the PTO lever. These are components of the basic circuit used with mechanical gearboxes. The standard starter motor with a 2.2 kW nominal power rating is the type with four poles and four brushes, with built-in electromagnet and control unit with positive meshing. The electromagnet contains two windings connected in parallel. One is the low resistance winding of the power coil, grounded by the engine, while the other is the high resistance winding of the retention coil, grounded by the body of the electromagnet. When the key-switch makes contact, with the gearbox and reduction unit in neutral and the PTO lever in the disengaged position, the coils of the electromagnet are energized and the plunger is magnetically attracted inside the electromagnet. This movement, which is transmitted by means of a positionable articulation, forces the control pinion to mesh with the ring gear of the flywheel. The moment in which the pinion touches the ring gear, the plunger of the electromagnet makes a series of contacts to directly power all four coils from the battery, thus supplying full power to the starter

1020-4

motor. At this point, one end of the power coil is connected to the battery positive by means of the ignition switch while the other end is connected to the positive by means of the solenoid valve contacts. This allows the power coil to be bypassed without power being drawn and the retention coil keeps the plunger of the electromagnet engaged on its own. The starter motor contains a single set of contacts and a plunger of the electromagnet in two parts, which completely close the contacts even when the pinion teeth are not perfectly aligned with those of the ring gear. When this occurs, an engaging spring compresses and forces the pinion to fully mesh as soon as the starter motor starts to turn. When the key switch is released, power is shut off both from the electromagnet and starter motor. By acting through the positionable articulation, the return spring of the electromagnet frees the control pinion from its meshed condition and re-opens the contacts of the solenoid valve. The pinion unit includes a roller meshing device that prevents the armature from turning too much if the pinion remains meshed in the flywheel ring gear after the engine has started.

P/N 3681774M1

Edition 01-2006

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM

TESTS Ignition system test on the tractor Use a battery/ignition tester (tester with a high discharge rate) with a 0-200V voltmeter and 0-500 A ammeter to quickly and easily identify faults in the ignition system and obtain conclusive results. Comply with the test procedures recommended by the manufacturer when test equipment is used. If test equipment is not available, use the following test procedure with a normal 0-20 V voltmeter and 0-500 A ammeter to check that the starter motor operates correctly without removing it from the engine. Prior to the test: - Make sure that the battery is fully charged - Make sure that none of the ignition system wires is broken or frayed and that none of the connections is slack. - Make sure that the engine is not seized.

Power draw in the starter motor circuit 1. Disconnect the ground wire (negative) from the battery (3). 2. Disconnect the positive battery wire from the starter motor (4). Connect the positive prod of an ammeter (1) to the positive battery terminal and the negative prod to the power terminal. 3. Re-connect the ground wire (negative) to the negative terminal of the battery (3). 4. Connect the positive prod of a voltmeter (2) to the positive battery terminal and the negative prod to the negative terminal of the battery. 5. Disconnect the wire from the closing solenoid valve of the injection pump.

4LA0064

6. Allow the engine to operate and check the readings on the voltmeter and ammeter. The voltage must remain constantly at around 12 V with a 250-300 A power draw. â&#x20AC;˘ If the power draw corresponds to the technical value, this means that the starter motor (4) operates correctly. If the voltage drops during the test, comply with the procedure described in the "Resistance in the ignition circuit" section.

P/N 3681774M1

Edition 01-2006

1020-5

SECTION 1020 - ELECTRICAL SYSTEM – IGNITION SYSTEM •

•

If the power draw is higher than the technical value, check the circuit as described below. If the ignition circuit tests are satisfactory, the starter motor is defective and must be demounted in order to identify the cause. If the power draw corresponds is less than the technical value, this means that the starter motor must be demounted in order to identify the cause.

Resistance in the ignition system circuit (voltage drop) If the power draw is excessive, check the circuit to find out what is causing the voltage drop between the individual components of the circuit itself.

4LA0065

2 Positive battery cable 1. Connect the positive prod of the voltmeter (1) to the positive terminal of the battery (2). 2. Connect the negative prod of the voltmeter to the power terminal of the starter motor (3). 3. Allow the engine to operate and check the reading on the voltmeter. If the voltage exceeds 0.2 Volts, check and tighten the cable connections. Check the voltage again and install a new cable if it is too high. Ground connection of the starter motor 1. Connect the positive prod of the voltmeter (1) to the casing of the starter motor (2). 2. Connect the negative prod of the voltmeter to the engine block (3). 3. Allow the engine to operate and check the reading on the voltmeter. If it is higher than 0.2 V, check the ground connections between the flange of the starter motor and the rear engine cover.

4LA0066

1020-6

P/N 3681774M1

Edition 01-2006

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM Battery ground cable 1. Connect the positive prod of the voltmeter (1) to the engine block (2). 2. Connect the negative prod of the voltmeter to the negative terminal of the battery (3). 3. Allow the engine to operate and check the reading on the voltmeter. If the voltage exceeds 0.2 Volts, check and tighten the ground cable connections. Check the voltage again and install a new ground cable if it is still too high. 2LA0501

STARTER MOTOR. REMOVAL - REFITTING 1. Disconnect the negative wire from the battery. 2. Loosen the nut and remove the power terminal (1). 3. Remove the two fixing bolts (3) of the starter motor (2) and remove it. 4. Work through the removal operations in reverse order to remount the starter motor.

4LA0045

P/N 3681774M1

Edition 01-2006

1020-7

SECTION 1020 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; IGNITION SYSTEM

1020-8

P/N 3681774M1

Edition 01-2006

SECTION 1030 ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM TABLE OF CONTENTS Description

Page

TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-4 Description of the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-4 Alternator operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-5 TESTS AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Precautions to take during the operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Preliminary inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Initial tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator connection test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Charge current and regulated voltage tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Alternator component tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1030-6 1030-6 1030-7 1030-8 1030-8 1030-9 1030-9

ALTERNATOR. REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1030-10

1030-2

P/N 3681774M1

Edition 01-2006

SECTION 1030 - ELECTRICAL SYSTEM – RECHARGING SYSTEM

TECHNICAL SPECIFICATIONS TYPE OF ALTERNATOR FEATURES

DENSO 32 A68-04700

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Negative ground

Spinning direction (viewed from pulley side). . . . . . . . . . . . . . . . . . .

clockwise

Voltage rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (V)

Maximum rotation rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (RPM)

18,000

Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (A)

90A

Voltage monitored by governor . . . . . . . . . . . . . . . . . . . . . . . . . (V)

14.2 - 14.8

Working temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (°C)

-30 - 90

Voltage governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Built-in

P/N 3681774M1

Edition 01-2006

1030-3

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM

DESCRIPTION AND OPERATION Description of the alternator All models are fitted with a Denso 90 A alternator, with internal cooling fan. The stator winding is ventilated by means of an air conveying diaphragm in the support on the rectifier link side and with peripheral openings around the support on the control side. The alternator is installed on the righthand side of the engine and is operated by a pulley via a V-belt. The alternators are equipped with a built-in governor. 90 A alternator 1. Battery power connection (terminal B+) 2. Alternator indicator and ignition switch connection.

1030-4

4LA0010

P/N 3681774M1

Edition 01-2006

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM 1

B+ IG B

IG P

PI F

4LA0031

5 2

Alternator charging circuit 1. 2. 3. 4.

Alternator Ignition switch Alternator charge indicator light Users

Alternator operation A current passes from the battery through the field winding of the rotor when the ignition key is turned. The circuit closes between the light that indicates the charge, terminal L of the alternator, the rotor field winding, the alternator governor and ground. At this point, the indicator light comes on and the rotor is partially magnetized. Three-phase alternate current is generated when the engine starts and the partially magnetized rotor turns inside the stator windings. A constant quantity of that current is converted into direct current by the three field diodes built into the rectifier unit.

P/N 3681774M1

Edition 01-2006

5. Battery 6. Electronic voltage governor circuit of the alternator 7. RPM meter signal

The direct current is then conveyed around the circuit again to increase the current that flows through the field winding of the rotor. This action leads to a continuous increase in the rotorâ&#x20AC;&#x2122;s magnetic field plus a rapid increase in current production. The luminosity of the indicator light diminishes during the voltage increase generated on the output (which reflects on terminal L) and when the voltage on terminal L is the same as that on the battery side, the indicator light goes out. The voltage continues to increase until it reaches the preset regulated voltage level.

1030-5

SECTION 1030 - ELECTRICAL SYSTEM – RECHARGING SYSTEM The alternator will be unable to operate if the control belt breaks, thus the charge indicator will remain on to warn of the fault.

4LA0027

3 Fan belt tensioner

1. Belt stretcher nut 2. Belt

TESTS AND TROUBLESHOOTING Precautions to take during the operation Take the following precautions to prevent the components of the alternator charging system from being damaged: • NEVER EVER MAKE OR BREAK any connection in the charging circuit, including the battery, when the engine is running. • NEVER EVER SHORT-CIRCUIT the positive terminal of the alternator to check whether this latter is working. • ALWAYS DISCONNECT the battery cables when the battery is recharged on the tractor with a battery charger. • ALWAYS COMPLY WITH the correct polarity when the battery is installed or when an auxiliary battery is used to start the engine. • DO NOT SHORT-CIRCUIT the input and output terminals of the voltage governor when the alternator is operating.

1030-6

P/N 3681774M1

Edition 01-2006

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM Preliminary inspections Before proceeding with the electrical tests, carefully inspect the charging system and electrical system in general. Make sure that none of the conductors or connections are broken and check that they are all firmly fastened. 1. Battery inspection Check all the battery components with a densimeter. The battery must be charged to at least 70% of its capacity and be efficient (see section 1040, page 5). 2. Control belt inspection Inspect the pulley and alternator belt to make sure that they are clean, with no traces of oil or grease and that they are in a good condition. Periodically check the tension of the alternator belt. If you think that the belt is not taut enough, check the stretcher as indicated below, with reference to fig. 3: - loosen the alternator fixing nut (2) on the stretcher bracket. - using a lever, move the alternator along the stretcher bracket until the correct belt (1) tension is obtained (10-11 mm), then re-tighten the fixing nut (2). The belt must be replaced if it is cracked or needs adjusting too frequently. 3. Indicator light inspection Turn the ignition key and make sure that the indicator light comes fully on. If the bulb is not burnt out, test the connections of the alternator winding as described in the "INITIAL TESTS" chapter of this section. If the indicator light is on, start the engine and allow it to run at a higher rate than idling. The indicator light must go out. If it fails to go out, stop the engine and remove the wire from terminal L. If the light now goes out, it means that one of the alternator components is defective.

P/N 3681774M1

Edition 01-2006

1030-7

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM Initial tests The initial tests can be conducted without removing any of the charging circuit components from the tractor. They allow you to check: - the condition of the alternator wire connections - the alternator charge current and controlled voltage - the voltage drops in the charging circuit of the alternator - the maximum output of the alternator - Test equipment required: - 0 to 30 V voltmeter with mobile coil - 0 to 1 V millivoltmeter - 0 to 110 A ammeter with mobile coil - 1.5 Ohm 110 A variable load resistance.

Alternator connection test 1. Disconnect the battery. 2. Disconnect the terminals (1) and (2) of the alternator. 3. Re-connect the battery and turn the ignition key to the ON position but without starting the engine. Connect a voltmeter between each terminal and ground. Battery voltage must be present. If there is no voltage, identify and repair a continuity fault in the external cable circuit. Refer to the wiring diagram in figure 2.

4LA0036

4 4. Connect terminal L of the indicator light to ground. The indicator light must come on. 5. Disconnect the battery and re-connect the previously disconnected connectors to the alternator. If the indicator light fails to come on when the wire is re-connected to the alternator, this means that there is a fault in the alternatorâ&#x20AC;&#x2122;s governor circuit or in that of the rotor. Make sure that terminal D+ is clean and then test the alternator components as described in this section.

1030-8

P/N 3681774M1

Edition 01-2006

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM Charge current and regulated voltage tests Make sure that all the tractorâ&#x20AC;&#x2122;s electrical users are off and that the ignition key is in the OFF position. 1. Disconnect negative battery terminal and terminal (1) of the alternator. 2. Connect an ammeter between the detached cable and alternator terminal (1). 3. Connect a voltmeter between terminal (1) of the alternator and ground. 4. Re-connect the battery. Start the engine and accelerate to 2000 RPM. Check the voltmeter and ammeter readings.

4LA0036

5 The voltmeter must give a higher value than the battery voltage and, when the ammeter reading drops below 10 A, the voltmeter reading must stabilize between 13.6 V 14 V. 5. Slowly increase the current charge (lowering the value of the resistance) until the ammeter reading becomes 40 A. 6. Check the voltmeter reading, which must not drop below 13.6 V. A reading of less than 13.6 means that there is a defective component in the alternator. Test the alternator components as described in this chapter. Alternator component tests The component tests, which must only be carried out if the INITIAL TESTS have identified a defective component in the alternator, allow you to check: - the governor; - the no-break condition of the rotor field windings; - the brushes, springs and contact rings of the rotor. The previously described component tests can be conducted with the alternator installed in the tractor. To test the other components, the alternator must be removed from the tractor.

P/N 3681774M1

Edition 01-2006

1030-9

SECTION 1030 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; RECHARGING SYSTEM

ALTERNATOR. REMOVAL - REFITTING Make sure that the ignition key is in the OFF position before disconnecting the alternator wires.

1. Raise the bonnet. 2. Disconnect the terminal (1) and the connection (2).

4LA0010

6 3. Loosen and remove the nut and bolt (1) that fixes the alternator to the belt tensioner. 4. Move the alternator in order to slacken the belt (2) thus removing it from the pulley. 5. Remove the nut (3) from the through bolt that fixes the alternator to the engine.

4LA0037

3 7

1030-10

P/N 3681774M1

Edition 01-2006

SECTION 1040 ELECTRICAL SYSTEM - BATTERY

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY TABLE OF CONTENTS Description

Page

TECHNICAL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-3 DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-3 BATTERY REMOVAL - REFITTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4 Refitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-4 MAINTENANCE AND BATTERY INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Relative density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Dry charged batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1040-5 1040-5 1040-6 1040-7 1040-7 1040-9

COMMON CAUSES OF BATTERY FAULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1040-12

1040-2

P/N 3681774M1

Edition 01-2006

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY

TECHNICAL SPECIFICATIONS FEATURES Voltage

(V)

TYPE OF BATTERY 12

Cold starting current (C.C.A)

800

Capacity

100

(Ah)

Number of elements Weight

(kg)

Ground terminal

6 ~ 20 Negative

DESCRIPTION AND OPERATION The battery is the maintenance-free "sealed" type. It is installed as standard supply in all models and is positioned behind the operator's seat. "Maintenance-free" means that the battery does not lose water from the electrolyte during normal charging conditions. The conditions that could lead to water leaks include charged prolonged beyond 14.4 V where gassing occurs as the battery fully charges. This can be caused by a defective charging system, by quickcharging equipment, etc. The three main functions of the battery are: - To provide a source of electric current for starting, ignition and the instruments. - To monitor the voltage of the electrical system. - To supply electric current when the power draws exceed the energy provided by the alternator.

P/N 3681774M1

Edition 01-2006

The battery is made so that each element contains positive and negative plates arranged alternately, one alongside the other. Each positive plate is separated from the negative plate by a separator with a porous and insulating casing. If one of the positive plates comes into contact with the negative plates in an element, this latter will short-circuit and be subjected to irreparable damage. All the positive plates are welded to a collector bar and form a positive terminal. All the negative plates are welded to a similar collector bar and form a negative terminal. Each positive plate consists of a lead grid with led peroxide plugged in the grid openings. The negative plates consist of a lead grid with spongy lead plugged in the grid openings. The plates are immersed in electrolyte formed by a solution of diluted sulphuric acid. The battery case is made of polypropylene.

1040-3

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY

BATTERY REMOVAL - REFITTING Removal 1. Raise the bonnet. 2. Loosen the bolts of both terminals and disconnect the negative (1) and positive cables (2) from the battery. Make sure that they do not touch the battery itself. 3. Loosen the battery fixing bolt (3) on the front part.

4LA0022

1 Refitting Work through the demounting procedure in reverse order when remounting the battery, and take the following precautions: - Make sure that the battery is clean and that there are no traces of spilt electrolyte on the outside. Make sure that the vents are completely installed. Smear Vaseline or similar on the terminals. Do not use conventional lubricating grease as this could cause electrolytic corrosion. - Make sure that the battery housing or supports and the terminals are clean, with no stones or small objects that could perforate the battery case. - Make sure that the polarity of the battery terminals is correct and that the terminal connections are firmly fastened.

1040-4

P/N 3681774M1

Edition 01-2006

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY

MAINTENANCE AND BATTERY INSPECTION Relative density The relative density of the battery acid indicates the charge status. When the battery is fully charged, the relative density of the electrolyte is at least 1.280 at 25°C. Alternatively, the approximate charge status can be measured with a digital voltmeter (± 0.01V) as follows: Less than 10.5 V Unserviceable battery* Less than 11.8 V Battery discharged Less than 12.3 V Battery half charged More than 12.6 V Battery fully charged * Consult the notes in chapter "TESTS" for instructions about how to recover a slightly sulphated battery. The battery voltage must be measured with the battery discharged and: A. After the battery has been discharged for at least 4 hours. B. Turn on the headlights for 2 minutes if the tractor has been used recently or if the battery has been charged recently. When a battery is discharged, the sulphuric acid in the electrolyte combines chemically with the plates and this action causes the relative density of the solution to diminish. A battery densimeter will determine the relative density of the electrolyte in an element and the quantity of unused sulphuric acid in the solution

P/N 3681774M1

Edition 01-2006

will indicate the charge degree of that element. The lower the temperature at which the battery must operate, the more the battery must be kept in fully charged conditions. For example, a battery with a relative density of 1.225 at 27°C (80°F) will operate the starter motor at mild ambient temperatures, but may not do this at low temperatures owing to inferior battery efficiency. Table 1 illustrates the effect of the temperature on battery efficiency. Table 1 Temperature

Efficiency of a fully charged battery

25.0°C -4.5°C -24.0°C -27.5°C -31.0°C -34.5°C -37.5°C

100% 82% 64% 58% 50% 40% 33%

Maximum battery life can be obtained by paying the necessary attention and making periodical inspections. The capacity delivered must not be exceeded by constant and excessive overcharging and the charging requisites must be maintained.

1040-5

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY Maintenance DANGER

Batteries contain sulphuric acid. When they are charged they generate a highly explosive mixture of hydrogen and oxygen gas.

Never use tools that produce flames or sparks to check the level of the battery acid. - Never remove the caps from the battery without protecting your eyes and hands. Take the following steps during battery maintenance: 1. Keep the electrolyte at the recommended level, i.e. 17 mm above the plates. Failing this, the acid will reach a high concentration that could damage the separators and impair the efficiency of the plates. 2. Use only distilled or demineralised water. Do not overfill and do not use tap water, rain water or water from other sources to top up the battery acid. 3. Always keep the battery at least 75% charged, otherwise the plates will become sulphated. This will lead to a drop in efficiency with possible damage from freezing at low temperatures. 4. Do not overcharge the battery as this can lead to excessive internal heat which damages the plate grid and leads to water leaks. 5. During rapid charges, make sure that the temperature of the battery does not exceed 50Â°C. 6. Do not add sulphuric acid to an element unless the battery acid has been lost through leaking. Before filling, make sure that the relative density of the solution is correct. Slow charging is the only method to use if the battery is to be fully charged. A high current battery charger can be used to charge the battery quickly, but this latter must subsequently be slowly charged in order to ensure full charging.

1040-6

P/N 3681774M1

Edition 01-2006

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY Dry charged batteries Dry charged batteries must be prepared for use in the following way: 1. Remove the vent plugs from the battery element. 2. Fill each element to the recommended level using electrolyte with a 1.260 relative density. The electrolyte must consist of diluted sulphuric acid at the preferable temperature of 21Â°-32Â° C. 3. After it has been filled, allow the battery to rest for 15 minutes, then check the level of the electrolyte again and top up if necessary. 4. Charge the battery for 4 hours with a 5-8 A current rating and make sure that all the elements freely develop gas. 5. Fit the vent plugs of the battery element back in place. Battery charging Before charging a battery: 1. Thoroughly clean the battery case and the covers of the elements with diluted ammonia or hot water, and clean the terminals. 2. Check the level of the electrolyte in each element and, if it is below the plates, add distilled water to bring it above plate level. Normal charge 1. With a slow battery charger, use a 3 to 6 A current for the time required to fully charge the battery. This operation could last 36 hours or more if the battery charge is very low. A seriously sulphated battery may not charge. When the battery is fully charged, the elements will freely develop gas and the relative density will remain constant. Disconnect the battery charger after three consecutive readings of the densimeter made each hour, that indicate that the relative density has stopped rising. 2. High charging current raises the temperature of the electrolyte and, unless the battery charger has an automatic timing or temperature device, the temperature of the electrolyte could exceed 50Â°C. This could lead to violent gassing and damage the internal battery components. 3. Check the level of the electrolyte in each element again, and add distilled water if necessary.

P/N 3681774M1

Edition 01-2006

1040-7

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY

DANGER

An explosive gas is produced when a battery is charged. Do not smoke or use naked flames when checking the level of the electrolyte and make sure that the battery charger is off before connecting or disconnecting, in order to prevent the formation of sparks which could ignite the gas.

Charging very discharged batteries The best way to charge a maintenance-free Pb-Ca battery is to use a constant voltage battery charger. For very low batteries, it is advisable to charge for 48 hours at 16 Volts with current limitation (30A per 60Ah). This system is self-regulating: a high current is supplied at the beginning (when the battery voltage is very low), while an increasingly lower current is then absorbed when the battery is fully charged (and its voltage is high). If only constant voltage battery chargers are available, it is advisable to comply with the voltage levels and time settings given in Table 2. The figures refer to batteries with very low charges. If the battery is only half discharged, allow half the time indicated (slow charging methods). Proportionally reduce the charging time for other conditions of discharge. When possible, use the slower recharging method to increase battery life. Table 2 Type of battery 100Ah Slow charging methods Quick charging methods (only for emergencies)

25 hours at 5A 12.5 hours at 10A 7 hours at 10A

If violent gassing or overflowing electrolyte occur when the battery is being charged, or the battery case becomes hot (50Â°C or more), reduce or stop charging temporarily in order to prevent the battery from being damaged.

1040-8

P/N 3681774M1

Edition 01-2006

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY Tests Before beginning the tests, check the battery to make sure that none of the vents are clogged, that there is no rust, raise vent caps and that the case is not cracked. Equipment required for the tests: - Densimeter - Battery starter tester (high current discharge tester) - Thermometer - Battery charger Relative density: This test establishes the battery charge status. 1. Take a reading with the float in the vertical position. 2. Adjust the reading of the densimeter for the temperature variations of the electrolyte by subtracting 4 points (relative density 0.004) for every 5.5°C below the temperature for which the densimeter is calibrated, and by adding 4 points (relative density 0.004) for every 5.5°C above this temperature. The following examples have been calculated using a densimeter with a 30°C setting. Example 1: Temperature less than 30°C Electrolyte temperature 19°C Densimeter reading 1.270 Subtract 11.0 x 0.004 5,5 Correct relative density = 1.262 Example 2: Temperature more than Electrolyte temperature Densimeter reading Add 10.0 x 0.004 5,5 Correct relative density = 3. Use the following table to ing condition.

30°C 40°C 1.220 0.007 1.227 establish the charg-

Charging condition

Relative density correct at 15°C

Relative density correct at 25°C

Average battery voltage

100% 75% 50% 25% Discharged

1.295 1.253 1.217 1.177 1.137

1.287 1.246 1.210 1.170 1.130

12.66 12.45 12.30 12.00 11.84

The relative density should not vary more than 0.025 points between the various cells.

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Edition 01-2006

1040-9

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY 4. If the relative density is 1.280 or more, the battery is fully charged and in good operating conditions. 5. If the correct relative density is less than 1.280, charge the battery and check the charging system to find out why the battery charge is low. If distilled water has been added recently, the battery must be recharged for a short period of time, otherwise the densimeter will be unable to give precise readings. If the battery has been charged in static conditions, the electrolyte that accumulates at the bottom of the elements will be more dense. The battery must be shaken every so often in order to mix the electrolyte: this will improve the charge current and will allow the densimeter to give more accurate readings during the tests. Efficiency test The efficiency test allows you to ascertain whether the capacity of the battery is sufficient to start the engine. The voltage reading obtained is used to identify the battery condition. Before conducting the test, make sure that the level of the battery acid is correct and that the open circuit voltage is 12,5V or more. The battery can be tested either on or disconnected from the tractor. 1. Set the current control switch of the battery starting tester (high current discharge tester) to the "off" position and the voltage selector switch to the nominal voltage of the battery or slightly higher. Connect the positive conductors of the tester to the positive battery terminal and the negative conductors to the negative battery terminal. 2. Turn the current control knob until the reading on the ammeter is half the cold starting current of the battery. Now read the voltage value. â&#x20AC;˘ If the reading is 9.6 V or more after 15 seconds, the battery has an acceptable delivered energy capacity and will promptly accept a nominal charge. â&#x20AC;˘ If the reading is below 9.6 V, the battery must be considered unsatisfactory for use and the charge must be tested as described below. CAUTION Do not leave the current charge on the battery for more than 15 seconds.

1040-10

P/N 3681774M1

Edition 01-2006

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY Test charging: only batteries that have not passed the previous capacity test need to be subjected to this test. 1. Connect the positive conductors of the starter tester to the positive battery terminal and the negative conductors to the negative battery terminal. 2. Connect the positive conductor of the battery charger to the positive battery terminal and the negative conductor to the negative battery terminal. 3. Turn the battery charger timer beyond the "3 minutes" charge indication and then to the "3 minutes" mark again. 4. Set the charge current as near to 40 A as possible. 5. Check the voltmeter reading after 3 minutes of this quick charge. • If the total voltage exceeds 15.5 V, the battery is unsatisfactory. It is probably sulphated or worn and must be replaced.

Relative density

Rapid charge until:

1.150 or less

60 minutes

from 1.151 to 1.175

45 minutes

from 1.176 to 1.200

30 minutes

from 1.200 to 1.225

15 minutes (Slow charging only)

A slightly sulphated battery can be recovered by using a battery charger of the multiple type, with a 50 V higher open circuit voltage limit. In view of the high resistance of a sulphated battery, a higher voltage value must be selected initially in order to overcome the sulphation resistance. There may be no visible acceptance of the charge at the beginning. A small charge will appear after a few minutes, followed by a fast increase in the amperage. The current must not exceed 14 A and the temperature of the electrolyte must not exceed 50 °C. When the current has stabilized, restore the voltage until a permanent 5 A has been reached. Continue with this current until the relative density of the electrolyte stops rising at about 1.275-1.280 at 20°C. This could require 48 hours charging. Allow the battery to rest for 24 hours and then conduct the previously described capacity test. •

If the total voltage is below 15.5 V, test the relative density of each element and recharge the battery according to the following scale:

P/N 3681774M1

Edition 01-2006

1040-11

SECTION 1040 - ELECTRICAL SYSTEM - BATTERY

COMMON CAUSES OF BATTERY FAULTS 1. 2. 3. 4. 5.

Internal circuit open. Internal short-circuit. Leaking electrolyte. Separation of active substances from the grids. Accumulation of sulphate crystals too large to disperse. These faults normally have the following causes: 1. Faulty components inside the element. 2. Excessive development of crystals which could perforate the separators and cause short-circuits. 3. Excessive overload (faulty operation of the charging system, rapid charging and high voltage restoration techniques, operation at very high temperatures). 4. Freezing electrolyte. A fully charged battery does not freeze down to -65°C. A 50% charged battery freezes between -17°C and -27°C. A completely discharged electrolyte freezes between -3°C and -11°C. An excessively high fast charge and gassing also cause the active substances to separate from the grids. Separation destroys the chemical function of the battery. 5. Crystals develop whenever batteries are left to remain discharged. High temperatures and lengthy discharge periods favour this condition. It is unlikely that a battery can be recovered on a vehicle after a week, at ambient temperature. Recharging will require a higher constant voltage. After 3 weeks, the battery will have been subjected to a permanent degradation and the previously described procedure must be used in order to charge a "very discharged" battery. Batteries last a long time when they are fully charged. Pb-Ca batteries discharge 3% per month. This means that a battery takes 16 months for its charge to become halved. The inactive charge is about 50mA on tractors. To forecast discharging on a static vehicle, add this value as though it corresponded to about 8Ah per week. It is worthwhile noting that if a battery begins to fade during the starting phase, it is better to stop for two minutes and allow it to recover. The colder the temperature, the longer the battery will take to recover.

1040-12

P/N 3681774M1

Edition 01-2006

SECTION 1050 ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS TABLE OF CONTENTS Description

Page

ELECTRICAL SYSTEM COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-3 LOCATIONS OF FUSES AND RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7 Main fuse box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7 Main fuse box location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-7 FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-8 MAXI FUSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-9 MAIN FUSE BOX RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-9 REAR CAB PILLAR FUSE BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-10 CAB REAR PILLAR RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-11 Relays location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-11 TURN INDICATOR AND HAZARD LIGHTS BLINKERS – NAO ECU (NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-12 POWER SOCKET - 7-PIN JOINT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-12 COLOUR CODES OF THE ELECTRICAL WIRES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-13 IDENTIFICATION CODE OF THE WIRING DIAGRAMS AND CONNECTIONS . . . . . . . . . . . . . . . . . 1050-13 WIRING DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-13 REAR PTO IGNITION, 4WD, BY SPEED SYSTEM, IGNITION SWITCH RELAY CIRCUIT (DIAGRAM A) . . . . . . . . . . . . . . . . . . . . 1050-14 DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING, FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT (DIAGRAM B) . . . . . . . . . . . . . . . . . . . . . . . . 1050-20 INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT (DIAGRAM C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-26 WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION), SPEED SHIFT (DIAGRAM D) . . . . . . . . 1050-34 CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN, CIGAR LIGHTER CIRCUIT (DIAGRAM E) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-40 ELECTRONICALLY CONTROLLED HYDRAULIC POWER LIFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic control unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ECU connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control panel connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1050-46 1050-46 1050-47 1050-48 1050-49

ELECTRONIC POWER LIFT CIRCUIT (DIAGRAM F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1050-50

1050-2

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

ELECTRICAL SYSTEM COMPONENTS 1

SOUND SYSTEM

INSTRUMENT

ALTERNATOR

ELECTRONIC BLINKER

GLOW PLUGS

CIGAR LIGHTER

LH HEADLIGHT (DIPPED/DRIVING BEAM)

RH HEADLIGHT (DIPPED/DRIVING BEAM)

NUMBER PLATE LIGHT

CAB LIGHT

ROTATING LIGHT

REVERSE INDICATOR LIGHT (Japan only)

LH FRONT WORKING LIGHT

RH FRONT WORKING LIGHT

LH REAR WORKING LIGHT

RH REAR WORKING LIGHT

BRAKE PEDAL COUPLING WARNING LIGHT

HORN

ALARM BUZZER

REVERSE INDICATOR BUZZER (Japan only)

LH BRAKE INDICATOR

RH BRAKE INDICATOR

LH FRONT TURN INDICATOR

LH REAR TURN INDICATOR

RH FRONT TURN INDICATOR

RH REAR TURN INDICATOR

LH FRONT SIDE LIGHT

LH REAR SIDE LIGHT

RH FRONT SIDE LIGHT

RH REAR SIDE LIGHT

RH TURN INDICATOR (NAO OUTFIT)

LH TURN INDICATOR (NAO OUTFIT)

STARTER MOTOR

WINDSCREEN WIPER MOTOR

WINDSCREEN WASHER MOTOR

P/N 3681774M1

Edition 01-2006

1050-3

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1050-4

REAR WINDOW WASHER MOTOR

REAR WINDOW WIPER MOTOR

CONDITIONER COMPRESSOR

CAB FAN

CONDITIONER FAN ADJUSTMENT RESISTOR

VEHICLE SPEED SENSOR PULL-UP RESISTOR

CONDITIONER FAN ADJUSTMENT RESISTOR

SPEED SHIFT TOGGLE RELAY

IGNITION SWITCH

FRONT PTO BUTTON

4WD/BY SPEED SWITCH

FRONT LOADER SWITCH

HAZARD LIGHT SWITCH

LIGHT STALK

ROTATING LIGHT SWITCH

FRONT WORKING LIGHT SWITCH

REAR WORKING LIGHT SWITCH

FRONT/REAR WINDOW WASHER SWITCH

WINDSCREEN WIPER SWITCH

REAR WINDOW WIPER SWITCH

CONDITIONER SWITCH

CONDITIONER FAN SPEED SELECTOR

REAR PTO SWITCH

DIFFERENTIAL LOCK BUTTON

HORN BUTTON ON LIGHT STALK

SPEED SHIFT BUTTON

BRAKE OIL LEVEL SENSOR

FUEL LEVEL SENSOR

PRESSURE SWITCH

ENGINE OIL PRESSURE SWITCH

AIR CLEANER VACUUM METER

GEARBOX OIL VACUUM METER

14 BAR PRESSURE SWITCH

TRAILER BRAKE PRESSURE SWITCH

CONDITIONER PRESSURE SWITCH

SYNCHRONISED PTO MICRO SWITCH

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

REVERSE SHUTTLE/GEAR IMMOBILISER MICRO SWITCH

GEAR LEVEL BY SPEED OFF MICRO SWITCH

SUPER FINAL DRIVE MICRO SWITCH

SLOW PTO MICRO SWITCH (540)

FAST PTO MICRO SWITCH (540E - 1000)

HANDBRAKE MICRO SWITCH

REVERSE POSITION REVERSER LEVER MICRO SWITCH (hydraulic gearbox outfit)

FORWARD DIRECTION MICRO SWITCH

BY SPEED PROXIMITY SENSOR

BRAKE PEDAL COUPLING SENSOR

PTO SPEED SENSOR

TRACTOR SPEED SENSOR (for odometer)

TEMPERATURE SENSOR FOR STARTER

COOLANT TEMPERATURE SENSOR

CONDITIONER FROST THERMOSTAT

AUXILIARY SOCKET IN CAB

NAO OUTFIT CONNECTOR

FUEL PUMP

STARTER

INJECTION PUMP

REAR PTO/BRAKE SOLENOID VALVE

FRONT PTO SOLENOID VALVE

4WD SOLENOID VALVE

BY SPEED SOLENOID VALVE

FRONT LOADER SOLENOID VALVE

DIFFERENTIAL LOCK SOLENOID VALVE

SPEED SHIFT SOLENOID VALVE

ENGINE WIRING CONNECTION (34 PIN)

100

REAR WIRING CONNECTION (34 PIN)

101

LH REAR LIGHT CONNECTION (6 PIN)

102

RH REAR LIGHT CONNECTION (6 PIN)

103

7-PIN SOCKET

104

WORKING LIGHT (version without cab)

105

ELECTRONIC POWER LIFT CONNECTION (4 PIN)

106

PLATFORM WIRING CONNECTION (10 PIN)

107

PLATFORM WIRING CONNECTION (18 PIN)

P/N 3681774M1

Edition 01-2006

1050-5

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1050-6

108

CONDITIONER WIRING CONNECTION (6 PIN)

109

LEFT SPEAKER

110

RIGHT SPEAKER

111

CAB CONNECTION (6 PIN)

112

CAB CONNECTION (2 PIN)

113

REAR WORKING LIGHT SWITCH (version without cab)

114

ENGINE POWER CONNECTION (2 PIN)

115

AIR SEAT ADJUSTMENT MOTOR

116

ELECTRONIC POWER LIFT UNIT

117

ELECTRONIC POWER LIFT CONTROL PANEL

118

EXTERNAL BUTTON LEFT INTERMEDIATE CONNECTION FOR POWER LIFT

119

EXTERNAL BUTTON RIGHT INTERMEDIATE CONNECTION FOR POWER LIFT

120

POWER LIFT UP SOLENOID VALVE

121

POWER LIFT DOWN SOLENOID VALVE

122

POWER LIFT ARM POSITION SENSOR

123

POWER LIFT EFFORT SENSOR

124

POWER LIFT UP LEFT CONTROL BUTTON

125

POWER LIFT DOWN LEFT CONTROL BUTTON

126

POWER LIFT UP RIGHT CONTROL BUTTON

127

POWER LIFT DOWN RIGHT CONTROL BUTTON

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

LOCATIONS OF FUSES AND RELAYS Main fuse box CAUTION When fuses are changed, make sure that the new fuse has the same rating as the old one. Even though they are interchangeable, use of different fuses would seriously impair tractor operation. Main fuse box location The fuse box is located inside the dashboard on the left side. To access the fuses, remove the cover panel by loosening the screw (1).

1 4LA0063

K12

K13

K10

K11

9 86

K14

87A

Front view

87 85

4LA0044

85 87a 86

Rear view

2 The fuses and relays are arranged in the fuse box as shown in the above figure.

P/N 3681774M1

Edition 01-2006

1050-7

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

FUSES Fuses

1050-8

CIRCUITS PROTECTED

Amp.

IGNITION SWITCH POWER RELAY FUSE

REAR PTO FUSE

FRONT PTO FUSE

IMMOBILISER FUSE

4WD/BY SPEED FUSE

BRAKE PEDAL COUPLING SENSOR FUSE

FRONT LOADER SOLENOID FUSE

GLOW PLUG RELAY FUSE

IGNITION FUSE

F10

ALTERNATOR FUSE

F11

D+ ALTERNATOR FUSE (FOR ELECTRONIC POWER LIFT)

F12

ELECTRONIC POWER LIFT IGNITION SWITCH FUSE

F13

STARTER/FUEL PUMP/INJECTION PUMP FUSE

7.5

F14

DIFFERENTIAL LOCK/BRAKE FUSE

F15

DIFFERENTIAL LOCK SOLENOID VALVE FUSE

F16

DIPPED BEAM FUSE

F17

DRIVING BEAM FUSE

F18

HAZARD LIGHT FUSE

F19

LIGHT STALK FUSE

F20

LH REAR INDICATOR FUSE

F21

RH REAR INDICATOR FUSE

F22

ROTATING HEADLIGHT FUSE

F23

CIGAR LIGHTER FUSE

F24

IGNITION SWITCH POWER FUSE INSTRUMENT - AUXILIARY SOCKET

F25

INSTRUMENT DIRECTOR POWER FUSE/BUZZER

F26

SPEED SHIFT SYSTEM FUSE

F27

REVERSE INDICATOR FUSE

7.5

F28

NAO UNIT FUSE

F29

CAB POWER FUSE

F30

AUXILIARY SOCKET FUSE

F31

WORKING LIGHT FUSE

7.5

F32

HORN FUSE

F33

30A AUXILIARY SOCKET FUSE

F34

AIR SEAT FUSE

7.5

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

MAXI FUSES Glow plug maxi fuse

General power supply maxi fuse

Cab maxi fuse

5LA0371

3 1. Maxi fuses 2. Electronic blinker

MAIN FUSE BOX RELAYS K01 K02 K03 K04 K05 K06 K07 K08 K09 K10 K11 K12 K13 K14

Ignition switch power relay Ignition switch power relay Ignition switch power relay Reverse indicator relay PTO immobiliser relay rear By speed system on relay By speed warning light relay Ignition relay Glow plug preheat relay Brake relay Differential lock self-retaining rely Dipped beam relay Driving beam relay Speed shift solenoid valve relay

P/N 3681774M1

Edition 01-2006

1050-9

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

REAR CAB PILLAR FUSE BOX The fuse box (1) connects to all consumers in the cab. It is located on the right rear pillar inside the cab.

4LA0014

4 List of functions: Fuses

Protected circuits

Amp.

Front windscreen wiper

Front working lights

Rear field lights

Conditioner solenoid valve

Conditioner pressure switch and compressor

7.5

Cab light - rear window wiper

4LA0047

1050-10

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

CAB REAR PILLAR RELAY CAUTION When the relay in the electrical system must be changed, make sure that the new relay is the same type as the old one. Even though they are interchangeable, use of different relays would seriously impair tractor operation. Relays location The relay wiring is located inside the right cab pillar. Remove the plastic cover to access the relays. The relay arrangement is shown in Fig.6 Relays: K15 Reverse indicator control relay (Japan only) K16 Windscreen wiper/washer relay K17 Conditioner fan relay K18 Front working light relay K19 Rear working light relay K20 Conditioner compressor relay K21 Conditioner fan relay

K17 K18 K15 K16 K19 K20 K21

4LA0003

P/N 3681774M1

Edition 01-2006

1050-11

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

TURN INDICATOR AND HAZARD LIGHTS BLINKERS – NAO ECU (NORTH AMERICA) The turn indicator blinker (1) and NAO unit (North America) are arranged inside the instrument panel.

4LA0050

POWER SOCKET - 7-PIN JOINT These are located on the rear left of the tractor (fig. 8) 1. 7-pin socket 2. Power socket

2LA0662

8 See fig. 9 (rear view) for position on the pins in the socket.

2LA0703

1050-12

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

COLOUR CODES OF THE ELECTRICAL WIRES A

Light blue

Brown

White

Black

Orange

Red

Yellow

Pink

Grey

Green

BLUE

Purple

Cross-section areas are 1 mm2 unless otherwise shown. When two letters are shown, the first identifies the basic colour and the second the longitudinal stripes. An asterisk appears in front of Kabelcar wire colours.

IDENTIFICATION CODE OF THE WIRING DIAGRAMS AND CONNECTIONS

0,5 -

RN -

WIRE CROSS-SECTION WIRE COLOUR

WIRING DIAGRAMS DESCRIPTION

DIAGRAM

Rear PTO ignition, 4WD, by speed system, ignition switch power relay circuit

Driving beams - dipped beam lights, hazard lights, differential locking, fuel pump, injection pump, starter circuit

Instrument, sensors, radio, rotating beam, cab light, air seat circuit

Working lights, reversing light (Japan version), speed shift circuit

Climate control, windscreen wiper/washer, passenger compartment fan, cigar lighter circuit

Electronic power lift circuit

P/N 3681774M1

Edition 01-2006

1050-13

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

REAR PTO IGNITION, 4WD, BY SPEED SYSTEM, IGNITION SWITCH RELAY CIRCUIT (DIAGRAM A) 5

Glow plugs

By speed system on relay

Brake pedal coupling warning light

By speed warning light relay

Starter motor

Ignition relay

Ignition switch

Glow plug preheat relay

Front PTO button

Ignition switch power relay fuse

4WD/by speed switch

Rear PTO fuse

Front loader switch

Front PTO fuse

Rear PTO switch

Immobiliser fuse

Synchronised PTO micro switch

4WD/by speed fuse

Reverse switch

Brake pedal coupling sensor fuse

Gear level by speed off micro switch

Front loader solenoid valve fuse

By speed proximity sensor

Glow plug relay fuse

Brake pedal coupling sensor

Ignition fuse

Rear PTO/brake solenoid valve

F10

Glow plug, alternator fuse

Front PTO solenoid valve

F35

Alternator ignition switch fuse

4WD solenoid valve

FU1

General fuse

By speed solenoid valve

Glow warning light

Front loader solenoid valve

Synchro warning light

Ignition switch power relay

By speed warning light

Ignition switch power relay

PTO warning light

Ignition switch power relay

IG alternator

Ignition switch power relay

Front PTO warning light

PTO immobiliser relay

1050-14

shuttle/gear

immobiliser

micro

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

REAR PTO IGNITION, 4WD, BY SPEED SYSTEM, IGNITION SWITCH POWER RELAY CIRCUIT - Diagram A

FU1 80A

44 2

F10

50A

15A

7,5A

F35

SCH. E

K8 92

73 CZ

80 K

72 W K

4LA0052

P/N 3681774M1

Edition 01-2006

1050-15

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

L 1.5 L 1.5 16R

16R

4RN

1.5M

2.5L

1.5N

1050-16

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

AV 4

3 2

B CB BG

58 11 *

Jumper valid for outfit without front PTO.

P/N 3681774M1

Edition 01-2006

1050-17

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

72 S M 2

71 2

ZN GM

73 BR

BR 3

B 2

MN 3

1050-18

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

2 1

BG BR

95 2

LR 2

2 1

P/N 3681774M1

Edition 01-2006

1050-19

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING, FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT (Diagram B) 3

Alternator

Ignition switch power relay

Electronic blinker

K10

Brake relay

LH headlight (dipped/driving beam)

K11

Differential lock self-retaining rely

RH headlight (dipped/driving beam)

K12

Dipped beam relay

Number plate light

K13

Driving beam relay

LH brake light

F11

RH brake light

F12

Electronic power lift ignition key fuse

LH front turn indicator

F13

Starter / fuel pump / injection pump fuse

LH rear turn indicator

F14

Differential lock / brakes fuse

RH front turn indicator

F15

Differential lock solenoid valve fuse

RH rear turn indicator

F16

Dipped beam fuse

LH front side light

F17

Driving beam fuse

LH tail light

F18

Hazard light fuse

RH front side light

F19

Light stalk fuse

RH tail light

F20

LH side light fuse

Hazard light switch

F21

RH side light fuse

Light stalk

FU2

General alternator fuse

Differential lock button

Differential lock warning light

Pressure switch

Alternator warning light

Forward direction micro switch

Ignition switch power

Fuel pump

Engine speed

Starter

Electronic power lift

Injection pump

7-pin socket

Diff lock solenoid valve

1050-20

D+ alternator fuse (for electronic power lift)

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

DRIVING BEAMS - DIPPED BEAM LIGHTS, HAZARD LIGHTS, DIFFERENTIAL LOCKING, FUEL PUMP, INJECTION PUMP, STARTER CIRCUIT (Diagram B)

10A

F19 M2

F20

F18

F21

4 X5

F15

10A

K13

10A

K12

B+

K10

VON

15A

F17

VCS

F16

15A

F14

15A

F13

7,5A

F12

100A

FU2

K11

X5 H

F11

79 X4

K10

K11

27 28 29 30

K13

K12

4LA0053

P/N 3681774M1

Edition 01-2006

1050-21

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

Pos.1

2 5

Pos.2

HM AN GR

Pos.3

1.5BN 1.5BN

Pos.5

Pos.6

B+

Pos.4

1050-22

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

pos.3 - G

pos.2 - N

pos.1 - B

pos.3 - V

pos.2 - M

pos.1 - B

pos. 1 1.5LN pos. 2 HR pos. 3 1.5R

pos. 4 pos. 5 1.5BN pos. 6 G-DIODO pos. 7

pos. 8 B pos. 9 V-DIODO pos.10 HG

P/N 3681774M1

Edition 01-2006

1050-23

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1.5BN 1 3

VN G

0.5G

V 0.5V

RV 2

R 1

1.5M

1.5R

1.5Z

59 BR

79 MV 2

RN 1

1050-24

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

P/N 3681774M1

Edition 01-2006

1050-25

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT (Diagram C) Instrument 1 Glow plug warning light 2 Alternator warning light 3 4WD warning light 4 Differential lock warning light 5 Driving beam warning light 6 Side/tail light warning light 7 LH turn indicator warning light 8 RH turn indicator warning light 9 Turn indicator 1st trailer warning light 10 Turn indicator 2nd trailer warning light 11 By speed warning light 12 Engine speed warning light 13 Speed shift warning light 14 Reverse gear warning light 15 Forward gear warning light 16 Front PTO warning light 17 Independent PTO warning light 18 Synchronised PTO warning light

Brake oil level sensor

Fuel level sensor

Engine oil pressure switch

Air cleaner vacuum meter

Gearbox oil vacuum meter

14 bar pressure switch

Trailer brake pressure switch

Super final drive micro switch

Slow PTO micro switch (540)

Fast PTO micro switch (540e - 1000)

Handbrake micro switch

PTO speed sensor

Tractor speed sensor (for odometer)

Coolant temperature sensor

Auxiliary cab socket

Cab light

NAO outfit connector

Rotating light

115

Air seat motor

Horn

Ignition switch power relay

Alarm buzzer

F22

Cab accessory /rotating light / horn fuse

RH turn indicator (NAO outfit)

F23

Auxiliary socket, cigar light fuse

LH turn indicator (NAO outfit)

F24

Ignition switch instrument power fuse

Vehicle speed sensor pull-up resistor

F25

Direct instrument power fuse / buzzer

Rotating beam switch

F36

Air seat power fuse

Horn button on light stalk

FU3

General fuse

1050-26

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

INSTRUMENT, SENSORS, RADIO, ROTATING BEAM, CAB LIGHT, AIR SEAT CIRCUIT (Diagram C) +30

60A

FU3

F 25

10A

F 24

15A

2 0A

F 36

F 23

F 22

15 82

31 2

HA2

B10

A8 B13

A10

A11

A21

A22

A23

A24

A1 B7

A25

A26

B22

A13

1SG

1BL

1SV

1HG

B14

A15

A16

A17

1BL

tbd

A14 B19

1HL

B16

B15

A19

A12

B17

B21

B20

88 41

1k2 R

115 M

85 65 66 67 68 74 69 75 76 62 77

82 83

4LA0054

P/N 3681774M1

Edition 01-2006

1050-27

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

1050-28

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

pos. 1 pos. 2 pos. 3 pos. 4 pos. 5 pos. 6 pos. 7 pos. 8 pos. 9 pos.10

0.5R 0.5HB 0.5RV 0.5BN TAPPO ZL 0.5LG 0.5RN 0.5ZB 0.5BG

pos.14 pos.15 pos.16 pos.17 pos.18 pos.19 pos.20 pos.21 pos.22

0.5B 0.5GM BL 0.5AV TAPPO 0.5MB

0.5VN HG pos.23 0.5G

pos.11 0.5BR

pos.24 0.5V

pos.12 0.5MN

pos.25 SV pos.26 BL

pos.13 0.5MB pos. 1 pos. 2 pos. 3

0.5GR 0.5HL 0.5CN

pos. 4 pos. 5 pos. 6 pos. 7 pos. 8 pos. 9 pos.10 pos.11 pos.12 pos.13

0.5R 0.5HB 0.5HM MB 0.5RN

pos.14 pos.15 pos.16 pos.17

3 1 8

7 13

19 26

20 25

SG 0.5CN 0.5BN

0.5N pos.18 MV pos.19 0.5B pos.20 pos.21 0.5VB pos.22 S pos.23 pos.24 pos.25 pos.26

3 1 8

7 13

19 26

20 25

P/N 3681774M1

Edition 01-2006

1050-29

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

10 B

1.5

CN RN

pos. 1 _ pos. 2 R pos. 3 RV pos. 4 _

62 0.5B

0.5BN

pos. 5 _ pos. 6 _

pos. 7 B

pos. 8 HG pos. 9 B pos.10 _

1050-30

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

S B

SG 3

P/N 3681774M1

Edition 01-2006

1050-31

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1 2 1

76 B

2 1

1050-32

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

82 B 2 2

83 RN 3

2 1

87 Pos1

2.5RN

Pos2

Pos3

2.5B

P/N 3681774M1

Edition 01-2006

1050-33

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION), SPEED SHIFT (DIAGRAM D) 12

Reverse indicator light (Japan only)

LH front working light

RH front working light

LH rear working light

RH rear working light

Reverse indicator buzzer (Japan only)

Speed shift toggle relay

Front working light switch

Rear working light switch

Speed shift button

Reverse shuttle lever switch (hydraulic gearbox version)

Forward direction micro switch

Speed shift solenoid valve

Ignition switch power relay

K14

Speed shift solenoid valve relay

K15

Reverse indicator control relay

K16

Windscreen wiper/washer relay

K18

Front working light relay

K19

Rear working light relay

F26

Speed shift fuse

F27

Reverse indicator and working light fuse

F28

Front working light fuse

F29

Rear working light fuse

F38

70 A general fuse

FU4

70 A general fuse

Reverse warning light

Forward direction warning light

Speed shift warning light

1050-34

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

FU4

F 38

70A

WORKING LIGHTS, REVERSING LIGHT (JAPAN VERSION), SPEED SHIFT CIRCUIT (DIAGRAM D)

K14

K19

K18

F 29

15A

F 28

15A

F 27

7,5A

F 26

K15

4 A .X S4

OUT

12 K14

K15

13 14 15 16

K18

K19

K16

4LA0055

P/N 3681774M1

Edition 01-2006

1050-35

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

13 H

HN HN

15 15

14 B B

1050-36

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

Pos.1

Pos.2

Pos.3

Pos.4

Pos.5

Pos.6

Pos.7

Pos.8

Pos.9

Pos.10

6 5 4 7

Pos.1

Pos.2

Pos.3

Pos.4

Pos.5

Pos.6

Pos.7

Pos.8

Pos.9

Pos.10

6 5 4 7

P/N 3681774M1

Edition 01-2006

1050-37

61 GM

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

MB 2

RN 1

79 MV 2

RN 1

98 2 1

2 1

1050-38

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

RELE' K16

RELE' K15 Pos.30

Pos.30

Pos.85

Pos.86 Pos.87

Pos.86

Pos.87

K16

RELE' K18 Pos.30

Pos.85 Pos.86

Pos.87

RELE' K19

2.5HN

Pos.30

Pos.85

Pos.86

Pos.87

2.5H

B B

H H

Pos.87a 85

K18

87a

Pos.87a 85

87a 87

Pos.87a

K15

87a

Pos.87a

K19

P/N 3681774M1

Edition 01-2006

1050-39

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN, CIGAR LIGHTER CIRCUIT (Diagram E) 1

Sound system

Cigar lighter

Windscreen wiper motor

Windscreen washer motor

Rear window washer motor

Rear window wiper motor

Conditioner compressor

Cab fan

Conditioner fan adjustment resistor

Front/rear washer switch

Windscreen wiper switch

Rear window wiper switch

Conditioner switch

Conditioner fan speed selector

Conditioner pressure switch

Conditioner frost thermostat

K16

Wiper/washer

K17

Conditioner fan

K20

Conditioner compressor

K21

Conditioner fan

F30

Wiper/washer fuse

F31

Cigar lighter fuse

F32

Conditioner compressor and pressure switch fuse

F33

Conditioner fan fuse

1050-40

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

CLIMATE CONTROL, WINDSCREEN WIPER/WASHER, PASSENGER COMPARTMENT FAN, CIGAR LIGHTER CIRCUIT (Diagram E)

SCH-A

F33

7,5A

30A

F32

56 H

86 4

K16

F31

20A

F 30

K20

K21 K17

70 7

K21

1 8

K20

K17

4LA0056

P/N 3681774M1

Edition 01-2006

1050-41

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

1 2

3 4

7 8

Pos.1 G

Pos.1 -

Pos.2 GN

Pos.2 -

Pos.3 -

Pos.4 -

Pos.4 R

Pos.5 -

Pos.6 -

Pos.7 AN

Pos.7

Pos.8 A

Pos.8 B

R R

1.5B

1.5GV

34 1.5B 1.5HR

1050-42

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1.5B 1.5GR

37 38 1.5B 1.5GR

P/N 3681774M1

Edition 01-2006

1050-43

M Pos.1

Pos.2

1.5GR

Pos.3

Pos.4

Pos.5

Pos.6

Pos.7

Pos.8

Pos.9

Pos.10

2.5B

2.5H

1.5VN 1.5VN

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

6 5 4 7

1 2

Pos.1

Pos.2

Pos.3

1.5VN

Pos.4

A B

1050-44

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

RELE' K16

RELE' K17

Pos.30

Pos.85

Pos.86 Pos.87

Pos.87

K17

RELE' K20

RELE' K21

Pos.30

2.5R

Pos.30

Pos.85

Pos.86 Pos.87

Pos.86

2.5RN

Pos.87

MB MB

Pos.87a 85

K20

87a

Pos.87a 85

87a 87

Pos.87a

K16

87a

Pos.87a

Pos.86

K21

P/N 3681774M1

Edition 01-2006

1050-45

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

ELECTRONICALLY CONTROLLED HYDRAULIC POWER LIFT Main components

4LA0135

31 The power lift control system consists of five fundamental components: A. Control panel located inside the cab on the righthand side B. ECU located inside the right-hand mudguard C. External buttons fitted on rear mudguards

1050-46

D. Position sensor located on arm supporting shaft E. Draft sensor located at the third point support F. Electrohydraulic distributor fitted on gearbox cover

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS Electronic control unit The ECU (1) is the "brain" of the electronic power lift control system. The ECU compares the signals from the sensors with those set by the operator on the control console. When the values transmitted by the sensors and the console do to correspond, the ECU activates the control block solenoid valves to raise or lower the arms until the set values and the measured values are the same. A specific safety system has been installed to prevent the electronic system from running after the engine is stopped. The ECU requires to power lines to work: the ignition switch power and the alternator power. The ECU will not run if either one of these two line is missing. Consequently, when the engine is not running, the electronically controlled power lift cannot be operated in any way. The ECU (1) is located inside the right-hand mudguard. To remove it, remove the panel from the rear side and loosen the fastening screws (G). Operate the metallic tab (H) to disconnect the connector.

P/N 3681774M1

Edition 01-2006

5LA0365

1050-47

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS ECU connection The 25-pin connection allows communication between the ECU and the other electrical and electronic components of the power lift system.

25 13

14 1

4LA0133

33 The pins used are listed below: PIN N.

1050-48

FUNCTION

Ground

Up solenoid valve

Potentiometer power

Adjustment - intermix

Alternator

Solenoid valve power

Not used

Up/down switches

Diagnostic LED

External control buttons

Oscillator LED

Control panel power

Sensor power

Down solenoid valve

Sensor ground

Working depth adjustment

Draft sensor

Position sensor signal

External control buttons

Shock absorber (on-off)

Maximum height adjustment

Not used

Down speed adjustment

Battery power

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS Control panel connection The 21-pin connector interfaces the ECU and the controls on the panel. The pins used are shown in the figure. 1

2 6

4 8

10 11 12 13 14 15

16 17 18 19 20 21 22 23 24

4LA0134

P/N 3681774M1

Edition 01-2006

1050-49

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

ELECTRONIC POWER LIFT CIRCUIT (DIAGRAM F) 105

Electronic power lift connection (pin 4)

116

Electronic power lift ECU

117

Electronic power lift control panel

118

Power lift external button left intermediate connection

119

Power lift external button right intermediate connection

120

Power lift up solenoid valve

121

Power lift down solenoid valve

122

Power lift arm position sensor

123

Power lift draft sensor

124

Power lift "up" left control button

125

Power lift "down" left control button

126

Power lift "up" right control button

127

Power lift "down" right control button

Ignition switch power

D+ alternator signal

Ground

Night light

1050-50

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

ELECTRONIC POWER LIFT CIRCUIT (Diagram F) 10

117 116 21 1 14 2 15

16 17

4 5

19 20

7 8

21 9 22 10 23 11 24 12 25 13

B H LN V LB RV G

V VG

G L BZ MN VN BV

330

R10

470

R11

16 17 09 07

H GV CN GN

390

560 12

560

Z GH A RN C

03 19

119

BV L

118 02

15R/2W

A B C D

M R14

20 18

10 1 23

1 23 V

120 122 4LA0130

P/N 3681774M1

Edition 01-2006

123

121

124

126

125

127

1050-51

ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

SECTION 1050 - ELECTRICAL SYSTEM – ELECTRICAL CIRCUITS

105 HM 4

1.5B

RN M

pos. 1 B LN pos. 2 LN pos. 3 BL

116

pos. 4 G 1 2 3 4 5 6 7 8 9 10 11 12 13

pos. 5 HM

15 16 17 18 19

pos. 6 CN pos. 7 -

20 21 22 23 24 25

pos. 8 Lpos. 9 MN B pos.10 B pos.11 Z

pos.14

H H

pos.15 V pos.16 RV pos.17

GV GV

pos.18 GV pos.19 GN pos.20

G G

pos.21 BZ pos.22 VN pos.23 -

pos.12 A

pos.24 HG

pos.13 C

pos.25 RN

1050-52

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

pos. 1 B

pos.12 MN

pos. 2 M

pos.13 Z

pos. 3 LN

pos.14

pos. 4 pos. 5 -

117

pos. 6 A pos. 7 RV 1

pos. 8 BL

10 11 12 13 14 15 16 17 18 19 20

21 22 23 24

118

pos.15 pos.16 L pos.17 VN pos.18 -

pos. 9 G

pos.19 H

pos.10 -

pos.20 -

pos.11 -

pos.21 HG

119

P/N 3681774M1

Edition 01-2006

1050-53

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

120

CN 1

121

CN 1

122

2 1

123

2 1

1050-54

P/N 3681774M1

Edition 01-2006

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

124 4

6 7

B A A 4

6 7

125

A 4

6 7

126

B A A 4

6 7

127

P/N 3681774M1

Edition 01-2006

1050-55

SECTION 1050 - ELECTRICAL SYSTEM â&#x20AC;&#x201C; ELECTRICAL CIRCUITS

1050-56

P/N 3681774M1

Edition 01-2006

SECTION 1100 CAB AND A/C SYSTEM

SECTION 1100 - CAB AND A/C SYSTEM TABLE OF CONTENTS Description

Page

CAB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . External cab components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior cab components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1100-3 1100-3 1100-4 1100-4

INSTRUMENTS AND CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-6 A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-8 INSTRUCTIONS FOR USING Starting . . . . . . . . . . Settings . . . . . . . . . . Stopping . . . . . . . . .

THE A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ................................................... ................................................... ...................................................

1100-9 1100-9 1100-9 1100-9

A/C SYSTEM OPERATING PRINCIPLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-10 A/C SYSTEM MAIN COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drier filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic expansion valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thermostatic switch (frost sensor) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1100-11 1100-12 1100-13 1100-13 1100-14 1100-15 1100-16

SWITCHING THE A/C ON AND SETTING THE TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-17 A/C SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-18 WARNINGS FOR REPAIRING THE CAB A/C SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-20 CAB A/C TROUBLESHOOTING OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-20 A/C SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1100-21

1100-2

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

CAB Main specifications The cab of the wide, four pillar type, is approved and compliant to safety standards in the event of roll-over. It is equipped with air conditioning system. The windscreen and rear tailgate can be pivot open to improve ventilation. The roof is provided with a clear top to improve visibility of front loaders. Four working lights are arranged on the roof to complete the basic specifications. The driving position offers a comfortable environment for operations. All controls are arranged for

simple, immediate operation. The steering wheel slant and height can be adjusted. Thanks to the adjustable seat, the position can be adapted to the driverâ&#x20AC;&#x2122;s needs. High pressurisation means that the vehicle can be used when working with plant protection products. Windows and doors are perfectly sealed. Soundproofing is excellent thanks to the use of specific materials, high trimming standards and quieter engines, with a noise level of 79 dBA.

5LA0438

P/N 3681774M1

Edition 01-2006

1100-3

SECTION 1100 - CAB AND A/C SYSTEM External cab components 1. 2. 3. 4. 5. 6. 7. 8.

Opening front window Front working lights Clear top and sun blinds Rotating light Adjustable rearview mirrors Rear field lights Opening rear window Opening left and right side doors

6 8 7

8 5LA0351

2 Interior cab components 1. Front windscreen wiper 2. Front window locks

5LA0352

3 1. 2. 3. 4.

Cab air recirculation Ventilation vents Ceiling light Rear window wiper

4 5LA0353

1100-4

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM The driverâ&#x20AC;&#x2122;s seat is equipped with devices for adjusting the suspension, the height and the distance referred to controls. 1. Longitudinal lock lever 2. Suspension adjustment knob 3. Height adjustment knob

The knob (4) is used to adjust the descent speed of the mechanically controlled power lift. 5LA0354

5 The steering wheel height can be adjusted by loosening the knob (1). The steering wheel slant can be adjusted after releasing the lever (2).

5LA0355

P/N 3681774M1

Edition 01-2006

1100-5

SECTION 1100 - CAB AND A/C SYSTEM

INSTRUMENTS AND CONTROLS 1

11 14

5LA0356

17 7

1100-6

Front zone controls

Right side controls

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

16. Electronic power lift control panel 17. Cigar lighter 18. PTO selection switch 19. 4RM and Fast-Run/Fast-Run selection switch 20. Differential lock switch 21. PTO speed selection lever 22. PTO engagement lever proportional to speed 23. Super final drive engagement lever

Light switch Reverse shuttle lever Instrument panel Steering wheel height adjustment Hazard lights and rotating light switch Ignition switch Clutch pedal Steering wheel slant adjustment Brake pedal Accelerator control pedal Gear lever Speed - Shift engagement button Range selection lever Auxiliary distributor lever Accelerator hand level

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM 1. Temperature adjustment knob 2. Fan speed selection knob 3. A/C button

1 2 3

5LA0357

8 1. Headlight switch 2. Rear light switch 3. Windscreen and rear window wiper switch

1 2 3 5LA0358

P/N 3681774M1

Edition 01-2006

1100-7

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM

WARNING

! -

Refrigerant must be handled with care to avoid injury to operators. Always wear gloves and eyewear. Liquid refrigerant can freeze the skin causing severe injury to eyes and even blindness in the severest cases. Keep the refrigerant container away from sources of heat because the pressure increase of refrigerant due to heat may make the container explode. Refrigerant may form a poisonous gas in contact with naked flames and heated metallic surfaces. The gas if inhaled may cause severe intoxication. Observe the simple precautions below to prevent accidents. The system must be discharged and charged in a ventilated environment away from naked flames. During the system discharging and charging operations, take the necessary precautions to protect your face - and especially your eyes - from refrigerant. Proceed as follows in the event of an accident: - If refrigerant gets splashed into your eyes, wash immediately with a few drops of mineral water then continue to rinse your eyes with a

1100-8

solution of boric acid and water (one tablespoon of acid in Âź of water). Call a doctor immediately. Freezing caused by the refrigerant can be treated by gradually warming up the injured part with cool water and applying a greasy cream. Call a doctor. The A/C system contains a mixture of pressurised oil and refrigerant: never loosen unions or work on pipes before discharging the system. Similarly, never loosen the compressor oil inspection cap when the system is charged. Do not heat up the refrigerant container. Over 50Â°C the increase of pressure due to heating is very rapid. Keep the A/C system away from sources of heat to avoid possible explosions due to the increase of gas pressure in the system piping.

Use only type-approved cylinders and other containers equipped with safety valves to transfer and store the refrigerant. Never charge refrigerant containers over 80% of their total capacity. Do not modify the calibration of safety valves and control components. Never connect a recovery/recycling and emptying/ recharging station to power mains other than those specified. Do not leave them powered between usages.

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

INSTRUCTIONS FOR USING THE A/C SYSTEM CAUTION When the engine is stationary, the A/C will not work because the compressor is operated by the engine. The conditioning system provides cool dehumidified air or warm dehumidified air. Proceed as follows: Starting Starting the system at low temperatures may cause damage to the compressor. Wait for the engine to warm up and the cab to reach 20Â°C before starting the A/C system. CAUTION Make sure that the A/C is off (3, fig. 8) before starting the engine. With the engine running and the fan on, press (3, fig. 8) to start the A/C system. The window on the top of the drier filter will appear clear and without bubbles after a few minutes of operation. Contact your dealer if this does not occur.

P/N 3681774M1

Edition 01-2006

Settings For correct climate control inside the cab, open the recirculation vents while the A/C system is running and keep the doors and the front and rear windows closed. For maximum cooling capacity, turn knob (1, fig. 8) anticlockwise all to the left. It is advisable to close the recirculation vents when working in dusty environments to increase cab pressure and prevent infiltration of dust inside. The dehumidifying action of the A/C system is provided at any internal temperature set by turning the knob (1, fig. 8). To make the temperature inside the cab comfortable after standing for a long time in sun, it is a good idea to get the tractor moving, switch on the A/C system and open the rear window for approximately one minute to let the overheated air out. Stopping Always switch the A/C system off by turning the knob (1, fig. 8), before stopping the engine. Then turn the fan knob (2) to the stopped position.

1100-9

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM OPERATING PRINCIPLES The A/C system is designed to create inside the cab the most comfortable environmental conditions for the driver. These conditions are essentially linked to four factors: - temperature - humidity - speed - purity of the air in the cab. It is not possible to define the optimal values of these quantities once and for all because they vary from person to person. However, it is possible to define the ranges within which most individuals feel most comfortable. As concerns temperature and humidity, a zone called the “wellbeing zone” can be defined in which the temperature-humidity pair corresponds to comfortable conditions. The chart shows that humidity is comfortable in the range from 30% to 70% (under 30% the nose and throat tissues tend to dry while over 70% it is formed an unpleasant feeling of humidity in various parts of the body). Temperature may vary from 18 to 28°C. The air flow speed must not be excessive to prevent annoyance. Values in the 0.07 - 0.25 m/s range are normally acceptable.

Simplified wellbeing chart 1. Unbearable cold feeling 2. Cold feeling 3. Wellbeing zone 4. Hot feeling 5. Unbearable hot feeling

No limits can be defined for air purity. It must be remembered that humans alter the composition of air in the environments where they live, increasing the level of carbon dioxide and humidity, decreasing the percentage of oxygen, etc. Such problems can be avoided by letting in small amounts of air from the outside, particularly for farming tractors working in very dust environments (ploughing, hay making, etc.), in which case dry filters are fitted on the external air vents. The application of A/C systems in tractors and farming machines in general therefore neutralises the negative effects on comfort caused by heat and humidity generated in the cab. The system works on the temperature and humidity features of the air present or let into the cab to obtain cooling and humidity levels comfortable for the driver. The working principle of an A/C system is similar to that of a domestic refrigerator: to cool an environment down, heat must be subtracted from it by means of a physical process (evaporation of a fluid) which absorbs heat from the surrounding environment. The liquid used, called refrigerant fluid, is a product characterised by a high refrigeration coefficient, low toxicity and good mixability with lubricant oils. Appropriate lines connect the various components and hold pressure in the system where the refrigerant circulates.

Relative humidity %

5LA0359

Temperature °C

1100-10

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM MAIN COMPONENTS The A/C system consists of essentially five elements: 1. Compressor 2. Condenser 3. Drier filter 4. Thermostatic expansion valve 5. Evaporator. To explain the operating cycle of the system, we will follow the course of the fluid from the compressor (1). The compressor takes in the refrigerant in cold vapour state at a pressure of 0.2-2.5 bars and compresses it to a pressure of 10-22 bars. The fluid heated by compression to 60-120 °C is let into the condenser serpentine (2) on the cab roof always in vapour state. The current of air produced by the fan on the cab roof near the condenser (2) cools the thermal exchange fluid. By effect of cooling, the coolant vapour reaches the condensation point from 40 to 70 °C according to the external temperature and turns liquid.

The fluid at the high pressure liquid state is purified by crossing the drier fluid (2) and goes to the expansion valve (4) which intercepting by a bottleneck the flow of coolant lowers its temperature. Through the valve (4), a part of the coolant is transformed into low temperature vapour and the mixture thus formed of low temperature and low pressure liquid and vapour is let into the evaporator (5). Here the fan causes a continuous circulation of air inside the cab on the evaporator fins (5), facilitating the absorption of heat by the mixture which is completely transformed into vapour. The process of evaporation of the refrigerant subtracts heat from the air with touches the evaporator (5) and therefore cools it, thus lowering the temperature in the cab. The flow of air on the cold surface of the evaporator (5) also condenses part of the air, thus lowering the degree of humidity in the cab atmosphere. The low pressure mixture at evaporator outlet (5) from 0 to 15°C is aspirated by the compressor (1) again to start a new cycle.

5LA0360

Simplified graphic representation of the system 4. Expansion valve and thermostatic sensor 5. Evaporator.

1. Compressor 2. Condenser 3. Drier filter

P/N 3681774M1

Edition 01-2006

1100-11

SECTION 1100 - CAB AND A/C SYSTEM Compressor The compressor compresses and circulates the refrigerant inside the system. The R134a refrigerant is used by the compressor. Important notes: Never keep the compressor oil container open. Make sure the container is always well closed to prevent absorbing humidity that is harmful for the system. Never transfer the compressor oil from its container to another. Never add anything to refrigerant and to system oil. All additional substances may contain elements which are incompatible with the chemical base of the refrigerant and may decay the features of the fluid itself. Never use engine oil or other types of oil to lubricate the system and the compressor. WARNING

Relevant leakage of R134a will be accompanied by relevant leakage of compressor lubricant. Check the oil level in the compressor in these cases. Contact a MF dealership workshop if this type of problem occurs.

1100-12

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM Condenser The condenser transforms refrigerant fluid from vapour to liquid. Since this occurs by transfer of heat from the fluid to the external environment air, the condenser works in a similar way as the engine coolant radiator. It consists of a series of tubes inside which the refrigerant fluid circuits and a finned pack which pressed on the tubes covers them entirely with thin aluminium sheets for surrendering heat to the external environment. The condenser radiator is installed under the cover on the roof of the cab. A fan installed on the condenser takes in the air flow needed for heat exchange. Drier filter The drier filter is installed on the condenser on the cab roof and is connected to the expansion valve by a pipe. It has two fundamental purposes: - It acts as a filtering element for liquid particles (water) and solid particles which form in the system. - It acts as a reservoir-plenum for the coolant during the various variable load stages. Eliminating that water from the system is important to prevent the creation of corrosion which could deteriorate system components. For this purpose, particular substances capable of absorbing humidity are housed in the filter. Also solid components such as sand, mechanical particles originated from compressor wear, oxides, tube particles can cause damage to the system and are therefore withheld by appropriate filters.

P/N 3681774M1

Edition 01-2006

1100-13

SECTION 1100 - CAB AND A/C SYSTEM Thermostatic expansion valve This device reduces the pressure of the refrigerant fluid at condenser outlet so that the fluid circulating the evaporator can change state and thus subtract heat from the air to be cooled. The expansion valve has two fundamental tasks: - metering: the calibrated hole (6) inside the valve body creates a pressure difference of the refrigerant fluid between inlet (4) (liquid state) and outlet (7) (mixed liquid/vapour state); the calibrated hole (6) also atomises the liquid to vapour before evaporation; - modulation: inside the valve body a thermostatic sensor slides between the maximum opening and maximum closing positions to meter the fluid flow to the evaporator and obtain complete evaporation. If the thermostatic sensor (2) detects a temperature increase of the fluid at evaporator outlet, it increases refrigerant flow. A decrease in temperature or increase in compressor flow rate (due to increase of engine speed) causes instead a decrease of refrigerant coolant flow rate in the evaporator. The expansion valve is fitted on the inlet union (7) of the evaporator and being part of the internal refrigerant gas modulating system is fully automatic and does not require particular maintenance. Operation can be checked with the conditioning system fully charged.

1100-14

5LA0361

12 Block expansion valve 1. 2. 3. 4. 5. 6. 7.

From the evaporator outlet union Thermostatic sensor To the compressor suction union From the drier filter Spring Calibrated hole and ball To the evaporator inlet union

Replace the valve in the event of a failure.

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM Evaporator The refrigerating cycle is completed inside the evaporator. The refrigerant let out by the expansion valve is a mixture of vapour and liquid at low temperature and pressure. Through the evaporator, it absorbs heat from the environment to be treated, vaporises and having developed the required refrigerating effect is taken in by the compressor in vapour state. The operation of the evaporator is controlled by the expansion valve which controls exactly the quantity of refrigerant needed to produce the required air treatment. The evaporator operation is exactly opposite to that of the condenser, buts its basic structure is identical. The main dimensions and the configuration of the internal hydraulic circuit change. The evaporator is responsible also for a further function: dehumidifying air. Since the air that crosses the evaporator contains a certain amount of humidity, the optimal degree of wellbeing is not reached if this is not carefully controlled and eliminated. The elimination of some of the humidity, in the form of condensation, is performed by the evaporator fins as the air cools down. The centrifuge fan takes in ambient air making it cross the finned pack so to cool it, dehumidify it and convey it back into the cab. The casing forms the housing of the finned pack and the fan is provided with a container for collecting condensation which is then conveyed outside by drain tubes.

P/N 3681774M1

Edition 01-2006

1100-15

SECTION 1100 - CAB AND A/C SYSTEM Thermostatic switch (frost sensor) The thermostatic switch or thermostat for short is a safety device provided with a serpentine sensor which, appropriately inserted on the evaporator outlet pipe, constantly detects the temperature. The sensor serpentine is indeed filled with a special gas whose variation in volume depending on the temperature of the evaporator allows, by acting on a membrane connected to a complex mechanism, the opening or closing of an electrical circuit connected to the electromagnetic clutch of the compressor which causes the latter to be switched on or off. The serpentine thermostatic sensor therefore avoids that the evaporator in the presence of very humid air freezes and obstructs the circulation of air to the cab. For this reason, it is very important following replacements and maintenance to arrange the serpentine thermostatic sensor back on the evaporator outlet pipe. Hold the two in contact with insulating tape so that the system will work correctly. Replace the serpentine thermostatic switch in the event of faulty operation.

1100-16

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

SWITCHING THE A/C ON AND SETTING THE TEMPERATURE The cab A/C system works when the ignition key is on. When the engine is stationary, the A/C will not work because the compressor is operated by the engine.

Make sure the A/C system is off before starting the engine. Always switch the fan on before the A/C system. The A/C system cannot work with the fan off.

1. Set the fan knob (2) to the required speed. 2. Press button (3) to switch the A/C on. 3. Adjust the knob (1) to select the required temperature and the fan speed.

1 2 3

5LA0357

13 The flow of air into the cab can be directed by appropriately turning the vents (1). Climate controlled air recirculation is obtained by opening the rear ventilation vent (2).

1 2

5LA0362

P/N 3681774M1

Edition 01-2006

1100-17

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM MAINTENANCE Check efficiency and correct operation of the system at the beginning of the usage season. If the charged system has remained off for a long time, the oil may have flowed from the compressor to other parts of the system and must flow back. For this purpose: 1. Start the engine and run it at 1500 rpm for approximately 10 minutes. 2. Set the fan to the maximum speed and switch the A/C on. 3. Check that the ratio between external temperature and temperature measured at the vents inside the cab respects the values shown in the table.

External air

20°C

Air at vent outlet (inside cab)

27°C

4 - 8°C

28°C

35°C

6 - 12°C

36°C

43°C

12 - 20°C

If the values are respected, it means that the A/C system is working correctly. Simply inspect the following main components: 1. COMPRESSOR: check fastenings, tension of drive belt and oil level. 2. CONDENSER: check fastenings and finned surfaces which must not present excessive deposits. Straighten any bent fins. Check the EVAPORATOR (9) and CONDENSER (5) in the same way.

3. DRIER FILTER: useful indication on system operation can be understood by observing the inspection glass of the filter as shown below. Replace the drier filter after two repair interventions on the system. 4. EXPANSION VALVE The valve does not require maintenance. Call MF specialised personnel in the event of faulty operation. If the temperature at vent outlet does not comply with the data shown in the table, seek the trouble causing system inefficiency as shown below.

1100-18

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM 1

5LA0363

A/C system schematics 1. 2. 3. 4. 5.

Compressor Suction tube (low pressure) Delivery tube (high pressure) Hot air Condenser

P/N 3681774M1

Edition 01-2006

6. 7. 8. 9. 10.

Drier filter Warning light glass Expansion valve and thermostatic sensor Evaporator Dry, dehumidified air

1100-19

SECTION 1100 - CAB AND A/C SYSTEM

WARNINGS FOR REPAIRING THE CAB A/C SYSTEM

WARNING

Always run the recovery, recirculation and recharging operation on the system when replacing one or more system components as shown on page 9

Important notes: When disassembling system tubes, place plastic caps on the extremities to prevent entrance of humidity and dust which could damage the system. When loosening fittings, always use two tools to prevent abnormal twisting.

CAB A/C TROUBLESHOOTING OVERVIEW Three main cases of faulty operation may occur: - the system does not work at all - the system does not provide sufficient cooling action - the compressor is not running smoothly. Given that insufficient cooling may be caused by problems external to the A/C system, generally a mechanical and visual inspection is sufficient to verify system efficiency. This information may be completed by an electrical test. At this point, if you still have not identified the fault, run a detailed troubleshooting procedure by analysing pressures in the various parts of the sys-

1100-20

tem, as shown on the following pages. Visual component inspection These checks must be performed with the engine stationary and the heating and A/C system off. - Check cleanness of external cab air vents. - Look for visible leakage of refrigerant from system pipes and fittings. - Check cleanness of engine radiators, condenser and evaporator. - Check that the thermostatic sensor is in contact with the evaporator outlet pipe with insulating tape to ensure correct operation of the system. Run a detailed troubleshooting procedure of the A/C system as described below.

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM TROUBLESHOOTING 1

THE SYSTEM DOES NOT WORK

Check the system fuses.

2. 3.

Check compressor belt tension. Check if current reaches the clutch coil. Make sure that the ground contact is efficient.

6. 7.

P/N 3681774M1

Edition 01-2006

Check the control devices and the systems, relays, wiring, thermostat, etc. Visually check conditions of all fittings and pipes. Check the distance (play) between front plate and pulley of the electromagnetic clutch.

1100-21

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM TROUBLESHOOTING (CONTINUED) 1

INSUFFICIENT COOLING

HIGH EXHAUST PRESSURE AND/OR HIGH SUCTION PRESSURE

LOW EXHAUST PRESSURE AND/OR LOW SUCTION PRESSURE

EXCESSIVE REFRIGERANT IN THE SYSTEM Drain refrigerant in excess.

Insufficient refrigerant. This may be caused by minor leaks. 1. Check for leaks and eliminate them. 2. Add refrigerant.

NORMAL EXHAUST PRESSURE AND/ OR NORMAL SUCTION PRESSURE

N.B.: The low pressure gauges during the test may point to the vacuum zone or indicate normal values. HUMIDITY IN THE SYSTEM 1. Drain refrigerant from the system. 2. Replace the drier filter. 3. Vent the system and recharge it.

CONDENSER May be obstructed or not receive sufficient flow of air. Clean the finned surface of the condenser. 1.

EXPANSION VALVE Check the valve. Replace it if it does not pass the test.

1100-22

P/N 3681774M1

Edition 01-2006

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM TROUBLESHOOTING (CONTINUED) 1

INSUFFICIENT COOLING

HIGH EXHAUST PRESSURE AND/OR NORMAL SUCTION PRESSURE

HIGH EXHAUST PRESSURE AND/OR LOW SUCTION PRESSURE

NORMAL EXHAUST PRESSURE AND/ OR NORMAL-HIGH SUCTION PRESSURE

Note: The high pressure gauge reading will not be constant and should not decrease. PRESENCE OF AIR IN THE SYSTEM 1. Recover and recycle system refrigerant. 2. Replace the drier filter. 3. Vent the system and recharge it.

BOTTLENECK Water or ice is formed downstream of the bottleneck (on drier filter or on condenser outlet to expansion valve). 1. Remove the concerned component, eliminate the bottleneck or replace the component.

FROST SWITCH The compressor electromagnetic clutch remains engaged with external temperatures lower than 30Â°C. 1. Check the switch. 2. Replace the frost switch if it is not working correctly being careful not to squeeze the serpentine. Install it the same position as before on the evaporator outlet pipe.

P/N 3681774M1

Edition 01-2006

1100-23

SECTION 1100 - CAB AND A/C SYSTEM

A/C SYSTEM TROUBLESHOOTING (CONTINUED) 1

COMPRESSOR AND ELECTROMAGNETIC CLUTCH

UNUSUAL NOISE WHEN CLUTCH IS ENGAGED

1. 2. 3.

4. 5. 6.

NO COOLING

Check all compressor fastening elements. Check the engine components near the compressor. Check if the electromagnetic clutch works intermittently or slips.

The compressor makes a noise or does not work at all.

Check the clutch bearing. Check pulley slipping of the electromagnetic clutch. Check compressor oil level.

1. 2. 3.

4. 5. 6. 7.

1100-24

UNUSUAL NOISE WITH CLUTCH RELEASED OR VIBRATION

1. 2.

Check electrical power. Check the distance (play) between front plate and pulley.

Check compressor belt state, correct tension and pulley alignment. Check the distance (play) between front plate and pulley of the electromagnetic clutch. Check power voltage of clutch, current draw, power wire and grounding.

Check pulley slipping of the electromagnetic clutch. Check whether refrigerant level is sufficient. Check the compressor for leakage. Check the system for leakage.

P/N 3681774M1

Edition 01-2006