New Holland 7630, 8030 Service Repair Manual 73403953 - PDF DOWNLOAD by www.heydownloads.com

SERVICE MANUAL

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

73403953 04/04/2014 EN

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

Clutch ....................................................................................... 18 [18.104] Clutch hydraulic release control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 73403953 04/04/2014

[21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

Four-Wheel Drive (4WD) system .................................................. 23 [23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

Power Take-Off (PTO) ................................................................. 31 [31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 [31.220] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4

Brakes and controls .................................................................... 33 [33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4

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[35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

Hitches, drawbars, and implement couplings.................................. 37 [37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

Steering..................................................................................... 41 [41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

Electrical systems ....................................................................... 55 [55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.610] Ground speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.030] Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.405] External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12

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INTRODUCTION

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Contents INTRODUCTION Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - Ecology And The Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 International symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules and signal word definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Abbreviation Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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INTRODUCTION

Advice All repair and maintenance works listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given; and using, whenever appropriate, the special tools. Anyone who carries out the above operations without complying with the instructions shall be responsible for the subsequent damages. The manufacturer and all the organizations of it's distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages due to the anomalous behavior of parts and/or components not approved by the manufacturer himself, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages due to an anomalous behavior of parts and/or components not approved by the manufacturer. The information in this manual is up-to-date at the date of the publication. It is the policy of the manufacturer for continuous improvement. Some information may not be updated due to modifications of a technical or commercial type, as well as to suit the laws and regulations of different countries. In case of questions, refer to your Sales and Service Networks.

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INTRODUCTION

Foreword - Ecology And The Environment Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, common sense should govern the use and disposal of products of a chemical and petrochemical nature. NOTE: The following are recommendations which may be of assistance: • Become acquainted with and ensure that you understand the relative legislation applicable to your country. • Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to their effect on man and nature and how to safely store, use and dispose of these substances. • Agricultural consultants will, in many cases, be able to help you as well.

HELPFUL HINTS • Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely until they can be disposed of in a proper way to comply with local legislation and available resources. • Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. They should not be allowed to get into the soil but should be collected and disposed of properly. • Repair any leaks or defects in the engine cooling or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding as penetrating weld splatter may burn a hole or weaken them, allowing the loss of oils, coolant, etc.

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INTRODUCTION

International symbols As a guide to the operation of the machine, various universal symbols have been utilized on the instruments, controls, switches, and fuse box. The symbols are shown below with an indication of their meaning. Heater plug for cold start

Turning signal

Power Take-Off (PTO)

Reaction control

Alternator charging

Activated memory

Transmission in neutral

Accessories socket

Fuel level

Turn signals

Creeper selection

Implement socket

Automatic fuel shut-off

Turn signals - one trailer

Low speed selection

Percentage slip

Engine speed (rpm x 100)

Turn signals - two trailers

High speed selection

Raising of the hydraulic lift

Hour meter

Wind shield washer

Road speed

Rear hitch lower

Engine oil pressure

Windscreen wash wipe

Differential Lock

Hydraulic lift height threshold

Engine coolant temperature

Heating temperature control

Rear axle oil temperature

Hydraulic lift disabled

Coolant level

Cab recirculation fan

Transmission oil pressure

Transmission filters and hydraulic filters

Machine lights

Air conditioner

Auxiliary Front Wheel Drive (AFWD) operated

Remote control valve extension

Main beam head

Air Filter Restriction

Warning!

Remote control valve command retraction

Low beam

Parking brake

Danger warning lights

Remote control valve flotation

Work lamps

Brake fluid level

Variable control

Malfunction! See Operatorâ&#x20AC;&#x2122;s

Stop lamp

Trailer brake

Pressurized! Open carefully

Malfunction! (alternative symbol)

Klaxon

Warning! Corrosive substance

Position control

Brake fluid level

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INTRODUCTION

Safety rules and signal word definitions Personal safety This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible death or injury.

Throughout this manual and on machine decals, you will find the signal words Danger, Warning, and Caution followed by special instructions. These precautions are intended for the personal safety of you and those working with you.

Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER DANGER indicates a hazardous situation which, if not avoided, will result in death or serious injury. The color associated with Danger is RED. M1169A

WARNING WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE. M1170A

CAUTION CAUTION, used with the safety alert symbol, indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. The color associated with Caution is YELLOW. M1171A

FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION MESSAGES COULD RESULT IN DEATH OR SERIOUS INJURY. Machine safety NOTICE: Notice indicates a situation which, if not avoided, could result in machine or property damage. The color associated with Notice is BLUE. Throughout this manual you will find the signal word Notice followed by special instructions to prevent machine or property damage. The word Notice is used to address practices not related to personal safety.

Information NOTE: Note indicates additional information which clarifies steps, procedures, or other information in this manual. Throughout this manual you will find the word Note followed by additional information about a step, procedure, or other information in the manual. The word Note is not intended to address personal safety or property damage.

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INTRODUCTION

Torque Use the torques in this chart when special torques are not given. These torques apply to fasteners with both UNC and UNF threads as received from suppliers dry, or when lubricated with engine oil. Not applicable if special graphite lubricants, Molydisulfide greases, or other extreme pressure lubricants are used.

Decimal hardware Grade 5 bolts, nuts, and studs Nm

Size

12 - 15 Nm 23 - 28 Nm 48 - 57 Nm 73 - 87 Nm 109 - 130 Nm 149 - 179 Nm 203 - 244 Nm 366 - 439 Nm 542 - 651 Nm 787 - 944 Nm 1085 - 1193 Nm 1519 - 1681 Nm 1980 - 2278 Nm 2631 - 2983 Nm Markings for Grade 5 hardware

1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

lb in/lb ft 108 - 132 lb in 204 - 252 lb in 420 - 504 lb in 54 - 64 lb ft 80 - 96 lb ft 110 - 132 lb ft 150 - 180 lb ft 270 - 324 lb ft 400 - 480 lb ft 580 - 696 lb ft 800 - 880 lb ft 1120 - 1240 lb ft 1460 - 1680 lb ft 1940 - 2200 lb ft

Grade 8 bolts, nuts, and studs Size 1/4 in 5/16 in 3/8 in 7/16 in 1/2 in 9/16 in 5/8 in 3/4 in 7/8 in 1 in 1-1/8 in 1-1/4 in 1-3/8 in 1-1/2 in

Nm 16 - 20 Nm 33 - 39 Nm 61 - 73 Nm 95 - 114 Nm 149 - 179 Nm 217 - 260 Nm 298 - 358 Nm 515 - 618 Nm 814 - 976 Nm 1220 - 1465 Nm 1736 - 1953 Nm 2468 - 2712 Nm 3227 - 3688 Nm 4285 - 4827 Nm Markings for Grade 8 hardware

NOTE: Use thick nuts with Grade 8 bolts.

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lb in/lb ft 144 - 180 lb in 288 - 348 lb in 540 - 648 lb in 70 - 84 lb ft 110 - 132 lb ft 160 - 192 lb ft 220 - 264 lb ft 380 - 456 lb ft 600 - 720 lb ft 900 - 1080 lb ft 1280 - 1440 lb ft 1820 - 2000 lb ft 2380 - 2720 lb ft 3160 - 3560 lb ft

INTRODUCTION

Metric hardware Grade 8.8 bolts, nuts, and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Nm 3 - 4 Nm 7 - 8 Nm 11 - 12 Nm 26 - 31 Nm 52 - 61 Nm 90 - 107 Nm 144 - 172 Nm 217 - 271 Nm 434 - 515 Nm 675 - 815 Nm 1250 - 1500 Nm 2175 - 2600 Nm Markings for Grade 8.8 hardware

lb in/lb ft 24 - 36 lb in 60 - 72 lb in 96 - 108 lb in 228 - 276 lb in 456 - 540 lb in 66 - 79 lb ft 106 - 127 lb ft 160 - 200 lb ft 320 - 380 lb ft 500 - 600 lb ft 920 - 1100 lb ft 1600 - 1950 lb ft

Nm 4 - 5 Nm 9 - 11 Nm 15 - 18 Nm 37 - 43 Nm 73 - 87 Nm 125 - 150 Nm 200 - 245 Nm 310 - 380 Nm 610 - 730 Nm 1050 - 1275 Nm 2000 - 2400 Nm 3500 - 4200 Nm Markings for Grade 10.9 hardware

lb in/lb ft 36 - 48 lb in 84 - 96 lb in 132 - 156 lb in 324 - 384 lb in 54 - 64 lb ft 93 - 112 lb ft 149 - 179 lb ft 230 - 280 lb ft 450 - 540 lb ft 780 - 940 lb ft 1470 - 1770 lb ft 2580 - 3090 lb ft

Grade 10.9 bolts, nuts and studs Size 4 mm 5 mm 6 mm 8 mm 10 mm 12 mm 14 mm 16 mm 20 mm 24 mm 30 mm 36 mm

Grade 12.9 bolts, nuts, and studs Nm Size lb in/lb ft Typically the torque values specified for grade 10.9 hardware can be used satisfactorily on grade 12.9 hardware. Markings for Grade 12.9 hardware

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INTRODUCTION

Steel hydraulic fittings 37Â° flare fitting Tube outside diameter/Hose inside diameter mm inch 6.4 mm 1/4 in 7.9 mm 5/16 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/6 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.4 mm 1 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread size

lb in/lb ft

8 - 16 Nm 11 - 22 Nm 14 - 34 Nm 20 - 57 Nm 34 - 79 Nm 54 - 108 Nm 81 - 135 Nm 102 - 158 Nm 169 - 223 Nm 285 - 338 Nm

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

72 - 144 lb in 96 - 192 lb in 120 - 300 lb in 180 - 504 lb in 300 - 696 lb in 40 - 80 lb ft 60 - 100 lb ft 75 - 117 lb ft 125 - 165 lb ft 210 - 250 lb ft

Straight threads with O-ring Tube outside diameter/Hose inside diameter mm inch 6.4 mm 1/4 in 7.9 mm 5/16 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/6 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.4 mm 1 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread size

lb in/lb ft

16 - 26 Nm 22 - 34 Nm 34 - 54 Nm 57 - 91 Nm 79 - 124 Nm 108 - 174 Nm 136 - 216 Nm 159 - 253 Nm 224 - 357 Nm 339 - 542 Nm

7/16-20 in 1/2-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-3/16-12 in 1-5/16-12 in 1-5/8-12 in 1-7/8-12 in

144 - 228 lb in 192 - 300 lb in 300 - 480 lb in 540 - 804 lb in 58 - 92 lb ft 80 - 128 lb ft 100 - 160 lb ft 117 - 187 lb ft 165 - 264 lb ft 250 - 400 lb ft

Split flange mounting bolts Nm

Size 20 - 27 Nm 27 - 34 Nm 47 - 61 Nm 74 - 88 Nm 190 - 203 Nm

5/16-18 in 3/8-16 in 7/16-14 in 1/2-13 in 5/8-11 in

180 - 240 lb 240 - 300 lb 420 - 540 lb 55 - 65 lb ft 140 - 150 lb

lb in/lb ft in in in ft

O-ring face seal end Nominal SAE dash size -4 -6 -8 -10 -12 -14 -16 -20 -24

Tube outside diameter mm in 6.4 mm 1/4 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/8 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.41 mm 1.0 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread size 9/16-18 in 11/16-16 in 13/16-16 in 1-14 in 1-3/16-12 in 1-3/16-12 in 1-7/16-12 in 1-11/16-12 in 2-12 in

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Nm 14 - 16 Nm 24 - 27 Nm 43 - 54 Nm 62 - 76 Nm 90 - 110 Nm 90 - 110 Nm 125 - 140 Nm 170 - 190 Nm 200 - 254 Nm

lb in/lb ft 120 - 144 lb in 216 - 240 lb in 384 - 480 lb in 552 - 672 lb in 65 - 80 lb ft 65 - 80 lb ft 92 - 105 lb ft 125 - 140 lb ft 150 - 180 lb ft

INTRODUCTION

O-ring boss end fitting or lock nut Nominal SAE dash size -4 -6 -8 -10 -12 -14 -16 -20 -24

Tube outside diameter mm in 6.4 mm 1/4 in 9.5 mm 3/8 in 12.7 mm 1/2 in 15.9 mm 5/8 in 19.0 mm 3/4 in 22.2 mm 7/8 in 25.41 mm 1.0 in 31.8 mm 1-1/4 in 38.1 mm 1-1/2 in

Thread size 7/16-20 in 9/16-18 in 3/4-16 in 7/8-14 in 1-1/16-12 in 1-13/16-12 in 1-5/16-12 in 1`-5/6-12 in 1-7/8-12 in

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Nm 23 - 27 Nm 34 - 41 Nm 61 - 68 Nm 81 - 88 Nm 115 - 122 Nm 129 - 136 Nm 156 - 169 Nm 201 - 217 Nm 258 - 271 Nm

lb in/lb ft 204 - 240 lb in 300 - 360 lb in 540 - 600 lb in 60 - 65 lb ft 85 - 90 lb ft 95 - 100 lb ft 115 - 125 lb ft 150 - 160 lb ft 190 - 200 lb ft

INTRODUCTION

Abbreviation Measurements Typical applications

Metric unit Name

Imperial unit Name

Symbol

Area (Land area)

mm²

acre square foot square inch square inch

ac ft² in² in²

ampere volt microfarad ohm

A V µF Ω

ampere volt microfarad ohm

A V µF Ω

kilonewton newton

kN N

pound pound

lb lb

newton per meter

N/m

pound per foot pound per inch

lb/ft lb/in

MHz kHz Hz

megahertz kilohertz hertz

MHz kHz Hz

r/min rpm

revolution per minute r/min ª rpm

kilometer meter centimeter millimeter micrometer

km m cm mm µm

mile foot inch inch

mi ft in in

kilogram gram milligram

kg g mg

pound ounce

lb oz

kilowatt watt

kW W

horsepower Btu per hour Btu per minute

Hp Btu/hr Btu/min

kPa

pound per square inch inch of mercury inch of water pound per square inch

psi inHg inH2O psi

hectare square meter

ha m²

square millimeter Electricity

Force

Force per length

Frequency megahertz kilohertz hertz Frequency − Rotational revolution per minute Length

Mass

Power

Pressure or stress (Force per area) kilopascal pascal megapascal

Pa MPa

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INTRODUCTION

Typical applications

Metric unit Name

Imperial unit Name

Symbol

Temperature (other than Thermodynamic) degrees Fahrenheit degrees Celsius °C Time hour h hour minute min minute s second second Torque (includes Bending moment, Moment of force, and Moment of a couple) newton meter Nm pound foot pound foot Velocity kilometer per hour mile per hour km/h meter per second m/s foot per second millimeter per second mm/s inch per second meter per minute m/min foot per minute Volume (includes Capacity) cubic meter cubic yard mm³ liter liter

l l

cubic inch US gallon UK gallon US quart UK quart fluid ounce

milliliter ml Volume per time (includes Discharge and Flow rate) cubic meter per m³/min minute liter per minute l/min milliliter per minute ml/min Sound power level and Sound pressure level decibel dB

Symbol

°F h min s lb ft lb in mph ft/s in/s ft/min yd³ cu yd in³ US gal UK gal US qt UK qt fl oz

cubic foot per minute ft³/min US gallon per minute US gal/min UK gallon per minute UK gal/min decibel

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SERVICE MANUAL Engine

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

73403953 04/04/2014

Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.102] Pan and covers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.110] Balancer and damper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.114] Pump drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.210] Lift pump and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9 [10.206] Fuel filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.10 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.11 [10.250] Turbocharger and lines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.12 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14 [10.414] Fan and drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15 [10.304] Engine lubrication system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16 [10.408] Oil cooler and lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17

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CONSUMABLES INDEX Consumable Loctite® 5205 Loctite® 5205

Reference Engine block cover Front - Assemble Engine block cover Front - Assemble

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PAGE 10.2 / 5 10.2 / 5

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Engine - 10 Engine and crankcase - 001

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Engine Remove the engine from the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Install in tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Crankcase Liner - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

DIAGNOSTIC Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Engine - Engine and crankcase

Engine - General specification Engine type Cycle Power Injection Number of cylinders Bore Stroke Total displacement Timing Start before T.D.C. End after B.D.C. Start before B.D.C. End after T.D.C. Valve clearance Intake Exhaust Fuel feed Injection type Control Injector Nozzle type Injection sequence Injection pressure Aspiration Turbocharging Turbocharger type Lubrication Oil pressure @ low idle Oil pressure @ fast idle Oil pan capacity Oil filter capacity Cooling Water pump Thermostat

General specifications 4 Cylinders 6 Cylinders Four-Stroke diesel engine Turbocharged with intercooler Direct 4 6 104 mm (4 in) 132 mm (5 in) 4485 cm³ 6728 cm³ 18.5 ° 29.5 ° 67 ° 35 ° 0.20 - 0.30 mm (0.008 - 0.012 in) 0.45 - 0.55 mm (0.018 - 0.022 in) Bosch high pressure common rail EDC7 UC31 CRIN 2 DLLA 1-3-4-2 1-5-3-6-2-4 250 - 1600 bar (3625 - 23200 psi) Intercooled Holset HX35

Honeywell GT25 0.7 bar (10 psi) 3.5 bar (51 psi) 15 l (15.85 US qt) 1 l (1.06 US qt)

Belt driven 79 - 83 °C (174 - 181 °F)

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Engine - Engine and crankcase

Clearance data Cylinder block and crankshaft components Cylinder barrels 104.000 - 104.024 mm (4.094 - 4.095 in) 0.4 mm (0.016 in) Oversize 103.739 - 103.757 mm (4.084 - 4.085 in) (*) Pistons Skirt height 49.5 mm (1.949 in) (*) Pin housing 38.010 - 38.016 mm (1.496 - 1.497 in) Piston (oversize) 0.4 mm (0.016 in) 0.28 - 0.52 mm (0.011 - 0.020 in) Protrusion 37.994 - 38.000 mm (1.496 - 1.496 in) Pin Piston pin - Pin housing 0.01 - 0.022 mm (0.0004 - 0.001 in) Piston ring landings 2.705 - 2.735 mm (0.106 - 0.108 in) Combustion 2.420 - 2.440 mm (0.095 - 0.096 in) (*) Intermediate 4.030 - 4.050 mm (0.159 - 0.159 in) Oil control Piston rings 2.560 - 2.605 mm (0.101 - 0.103 in) Combustion 2.350 - 2.380 mm (0.093 - 0.094 in) Intermediate 3.970 - 3.990 mm (0.156 - 0.157 in) Oil control Piston ring and ring landing clearance 0.100 - 0.175 mm (0.004 - 0.007 in) Combustion 0.060 - 0.110 mm (0.002 - 0.004 in) / 0.040 - 0.090 mm (0.002 - 0.004 in) (*) Intermediate 0.040 - 0.080 mm (0.002 - 0.003 in) Oil control Piston ring end gap 0.30 - 0.40 mm (0.012 - 0.016 in) Combustion 0.60 - 0.80 mm (0.024 - 0.031 in) Intermediate 0.30 - 0.55 mm (0.012 - 0.022 in) Oil control Connecting rod Small end housing 40.987 - 41.013 mm (1.614 - 1.615 in) Big end housing 72.987 - 73.013 mm (2.874 - 2.875 in) Small end bushing inside 38.019 - 38.033 mm (1.497 - 1.497 in) diameter Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.077 in) thickness Piston pin and bushing 0.019 - 0.039 mm (0.001 - 0.002 in) clearance Oversize big end bearing 0.250 mm (0.010 in) ; 0.500 mm (0.020 in) shells Crankshaft Main journals 82.99 - 83.01 mm (3.267 - 3.268 in) 68.987 - 69.013 mm (2.716 - 2.717 in) Crankpins Main bearing shell thickness 2.456 - 2.464 mm (0.097 - 0.098 in) Big end bearing shell 1.955 - 1.968 mm (0.077 - 0.078 in) thickness Main bearing bore 87.982 - 88.008 mm (3.464 - 3.465 in) No. 1,5 / 1,7 87.977 - 88.013 mm (3.464 - 3.465 in) No. 2,3,4 / 2,3,4,5,6 Bearing shell and journal clearance 0.041 - 0.119 mm (0.002 - 0.005 in) No. 1,5 / 1,7 0.041 - 0.103 mm (0.002 - 0.004 in) No. 2,3,4 / 2,3,4,5,6 Bearing shell and crankpin 0.033 - 0.041 mm (0.001 - 0.002 in) clearance Thrust journal 37.475 - 37.545 mm (1.475 - 1.478 in) Thrust bearing bore 32.180 - 32.280 mm (1.267 - 1.271 in) Thrust bearing 37.28 - 37.38 mm (1.468 - 1.472 in) Crankshaft end play 0.095 - 0.265 mm (0.004 - 0.010 in)

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Engine - Engine and crankcase

Clearance data Cylinder head and components Valve guide bore 7.042 - 7.062 mm (0.277 - 0.278 in) Intake valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 59.75 - 60.25 째 Exhaust valves 6.970 - 6.990 mm (0.274 - 0.275 in) Stem diameter Face angle 44.75 - 44.25 째 Valve stem and guide clearance 0.052 - 0.092 mm (0.002 - 0.004 in) Valve seat bore 34.837 - 34.863 mm (1.372 - 1.373 in) Intake 34.837 - 34.863 mm (1.372 - 1.373 in) Exhaust Valve seat outside diameter: 34.917 - 34.931 mm (1.375 - 1.375 in) Intake 34.917 - 34.931 mm (1.375 - 1.375 in) Exhaust Valve seat angle Intake 60 째 Exhaust 45 째 Valve sink 0.59 - 1.11 mm (0.023 - 0.044 in) Intake 0.96 - 1.48 mm (0.038 - 0.058 in) Exhaust Interference between valve seat and cylinder head 0.054 - 0.094 mm (0.002 - 0.004 in) Intake 0.054 - 0.094 mm (0.002 - 0.004 in) Exhaust Valve spring height 47.75 mm (1.880 in) Free Under a load equal to: 330.8 - 348.8 N (74.4 35.33 mm (1.391 in) 78.4 lb) Under a load equal to: 25.2 mm (0.992 in) 702 - 780 N (157.8 - 175.4 lb) Camshaft bore No.1 (flywheel side) 59.222 - 59.248 mm (2.332 - 2.333 in) 54.089 - 54.139 mm (2.129 - 2.131 in) No. 2,3,4,5 / 2,3,4,5,6,7 Camshaft journals 53.995 - 54.045 mm (2.126 - 2.128 in) 1-5 / 1-7 Bushing inside diameter 54.083 - 54.147 mm (2.129 - 2.132 in) Bushing and journal clearance 0.038 - 0.162 mm (0.001 - 0.006 in) Cam lift 7.582 mm (0.299 in) Intake 6.045 mm (0.238 in) Exhaust Tappet bore 16.000 - 16.030 mm (0.630 - 0.631 in) Tappet outside diameter Top 15.924 - 15.954 mm (0.627 - 0.628 in) 15.960 - 15.975 mm (0.628 - 0.629 in) Middle 15.924 - 15.954 mm (0.627 - 0.628 in) Bottom Tappets and bore clearance 0.025 - 0.070 mm (0.001 - 0.003 in) 21.965 - 21.977 mm (0.865 - 0.865 in) Rocker shaft 22.001 - 22.027 mm (0.866 - 0.867 in) Rockers 0.024 - 0.162 mm (0.001 - 0.006 in) Rockers and shaft clearance

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Engine - Engine and crankcase

Engine - Dimension Assembly dimensions Description Pistão e biela Cylinder sleeves Oversize Pistons supplied as spare part: Distance between the lower face of the piston and the centre of the pin holeX OD Oversize piston diameter Pin seat Piston - cylinder sleeves Piston projection above the cylinder block Piston pin diameter Piston pin - pin seat oversize Height of piston ring slots Top ring Middle ring Lower ring Ring thickness Top ring Middle ring Lower ring Tolerance between slots and rings Top ring Middle ring Lower ring Ring end opening in cylinder sleeve Top ring Middle ring Lower ring Diameter of smaller conrod seat Diameter of larger conrod seat Internal diameter of conrod bushing Thickness of bushings Virabrequim Diameter of trunnions Diameter of crankpins Trunnion bushing thickness Conrod bushing thickness Diameter of end bearings Diameter of intermediate bearings Trunnion bushing oversize End bushings Intermediate bushings Crankpin bushings oversize Width of side support trunnions Width of side support bearings Width of crankshaft half-rings Válvulas Diameter of valve guide seat in head Angle of valve faces: Intake

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104.0 - 104.024 mm 0.4 mm 12 mm 101.883 - 101.897 mm 0.5 mm 40.008 - 40.014 mm 0.252 - 0.294 mm 0.28 - 0.52 mm 37.994 - 38.000 mm 0.010 - 0.022 mm 2.705 - 2.735 mm 2.440 - 2.460 mm 4.030 - 4.050 mm 2.560 - 2.605 mm 2.350 - 2.380 mm 3.970 - 3.990 mm 0.100 - 0.175 mm 0.060 - 0.110 mm 0.040 - 0.080 mm 0.30 0.60 0.30 40.987 72.987 38.019 1.955

0.40 mm 0.80 mm 0.80 mm 41.013 mm 73.013 mm 38.033 mm 1.968 mm

82.990 68.987 2.456 1.955 87.982 87.977

83.010 mm 69.013 mm 2.464 mm 1.968 mm 88.008 mm 88.013 mm

0.064 0.059 0.033 37.475 31.730 37.28

0.095 mm 0.100 mm 0.041 mm 37.550 mm 32.280 mm 37.38 mm

8.019 - 8.039 mm 60 °

Engine - Engine and crankcase

Description Exhaust Valve stem diameter Intake and exhaust Clearance between valve rod and the respective guide Diameter of seat in head for valve seat Intake Exhaust External diameter of valve seat Intake Exhaust Valve seat angle in head Intake Exhaust Valve recess Intake Exhaust Clearance between valve seat and head Intake and exhaust Eixo de comando de válvulas Diameter of rear bushing seat Diameter of other shaft seats Diameter of bearings Internal diameter of bushings Clearance between bushings and bearings Clearance between seats and bearings Cam eccentricity Intake Exhaust

45 ° 7.960 - 7.980 mm 0.039 - 0.079 mm 46.987 - 47.013 mm 43.637 - 43.663 mm 47.063 - 47.089 mm 43.713 - 43.739 mm 60 ° 45 ° 0.336 - 1.072 mm 0.104 - 0.840 mm 0.050 - 0.102 mm 59.222 54.089 53.995 54.083 0.038 0.044

59.248 mm 54.139 mm 54.045 mm 54.147 mm 0.152 mm 0.144 mm

10.74 mm 11.02 mm

Engine - Torque Torques Bolt and thread M8 x 1.25 x 10

Component Oil spray nozzles in piston Crankshaft main bearing housings: 1st step 2nd step 3rd step Rear gearbox

— M8 x 1.25 x 40 M8 x 1.25 x 25 M10 x 1.5

Oil pump 1st step 2nd step Conrod cover bolts 1st step 2nd step 3rd step Oil sump fastening bolts (see Engine oil pan - Assemble (10.102)) Bolts No. 23 and 26 Bolts No. 3 - 10; 13 - 20; 24 - 25 Bolts No. 1 - 2 and 21 - 22 Bolts No. 11 and 12 Fuel pump installation

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M8 x 1.25 x 45 M8 x 1.25 x 30 M11 x 1.25

M10 x 1.5 x 45 M10 x 1.5 x 90 M10 x 1.5 x 125 M10 x 1.5 x 190

N.m 12 - 18 N·m 47 - 53 N·m 47 - 53 N·m 75 - 85 N·m 85 - 95 ° 20 - 28 N·m 20 - 28 N·m 44 - 54 N·m 20 - 28 N·m 27 - 33 N·m 55 - 65 N·m 55 - 65 ° 45 65 65 65

55 N·m 75 N·m 75 N·m 75 N·m

Engine - Engine and crankcase

Component Bolts Bolts Nuts Injector pump fastening nuts Pre-adjustments Final torque Rocker arm fastening Adjustment nut tightening Cylinder head fastening bolts (see Cylinder head - Install (10.101)). Valve cover. Water pump fastening Fan pulley fastening Fan hub fastening Lifting support fastening Crankshaft pulley Flywheel fastening to crankshaft 1st step 2nd step

Bolt and thread M8 M6 M6 M10 x 1.5 M8 3/4 in

Breather pump gear cover Injector nozzle cylinder head fastening Fuel bleed pump fastening Turbocharger exhaust manifold fastening Turbocharger lubrication tubing fastening Turbocharger discharge tubing fastening Alternator support fastening Alternator support thermostat cover installation Lower support installation Alternator upper part support fastening Alternator support fastening Alternator electrical connections Starter motor flywheel casing fastening Crankshaft bearing cap fastening bolts 1st phase 2nd phase 3rd phase Camshaft longitudinal fastening bolt Camshaft gear fastening bolt Conrod cover fastening bolt 1st phase 2nd phase

26 - 34 N·m 55 - 65 ° 75 - 95 N·m 75 - 95 N·m 44 - 54 N·m 44 - 54 N·m 20 - 28 N·m 55 - 65 N·m 20 - 28 N·m 37 - 49 N·m 30 - 40 N·m 20 - 28 N·m 20 - 28 N·m 20 - 28 N·m 20 - 28 N·m 44 - 54 N·m 37 - 49 N·m 8 - 12 N·m 44 - 54 N·m

(M12) (M8) (M8) (M10)

Special tools Description Injection pump gear extractor Tool for turning and locking the engine

10.1 [10.001] / 8

15 N·m 55 N·m 28 N·m 28 N·m

(M10 x 40)

(M10) (M12 x 1.5) (M8 x 1.25 x 16) (M8 x 1.25 x 30) (M8 x 1.25 x 30) (M10 x 1.25 x 25) (M10)) (M120 x 1.75 x 120) (Porca M6 x 1.0) (M10)

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20 - 28 N·m 20 - 28 N·m 8 - 12 N·m 37 - 49 N·m 28 - 38 N·m 5 - 19 N·m 34 - 48 N·m 105 - 115 N·m

Engine - Special tools Tool code 291182 380000988

10 50 20 20

(M8 x 1.25 x 25) (M8 x 1.25 x 25) (M6) (M10) (M10) (M12 x 1.75 x 25 (M10) (M12 x 1.75 - 10.9)

(M12 x 120) (M12 x 80) (M10 x 80) (M10 x 40) (M8 x 1.25 x 16) —

Flywheel cover engine fastening

N.m 20 - 28 N·m 9 - 11 N·m 9 - 11 N·m

44 - 56 N·m 74 - 86 N·m 85 - 95 ° 20 - 28 N·m 32 - 40 N·m 55 - 65 N·m 55 - 65 °

Engine - Engine and crankcase

Tool code 380001003 380001601 CNHT 0013 CNHT 0908 CNHT 0909 CNHT 0910 CNHT 0911

Description Device for checking the link conrod Adaptor for synchronising the injection pump Sliding Hammer Front retainer outer race extractor Rear retainer outer race extractor Injection nozzle extractor Supports to fasten engine on the trestle

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Engine - Engine and crankcase

Engine - Remove the engine from the transmission 1. Remove the discharge silencer. 2. Disconnect the hood connector and remove the hood group from the engine. Fig. 2 .

LAIL11TM0753A0A

LAIL11TM0754A0A

LAIL11TM0995A0A

3. Remove the engine starter according to the procedures described in Engine starter - Install (55.201). 4. Disconnect the hydraulic lines from the fuel sludge filter and reservoir return. 5. Disconnect the main connections from the engine. 6. Disconnect the water tube from the from the heating device valve joint located on the cylinder head. 7. Disconnect the hydraulic lines near the body housing. 8. Disconnect the brake lines from the control pumps. 9. Disconnect the left flexible line from the heating device to the cab, near the body housing. 10. Disconnect the quick connectors from the air conditioner system. 11. Connect the engine to a suitable winch. Remove the bolts fastening the engine to the transmission. Carefully remove the engine from the transmission, making sure that all the cables and tubes are disconnected. Place the engine on a suitable trestle to repair it.

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Engine - Engine and crankcase

Engine - Place on stand Prior operation: Removing the engine from the transmission Engine - Remove the engine from the transmission (10.001) NOTICE: See the specific procedures for the engine removal operations. The engine removal, disassembly and reassembly operations must be performed by qualified persons using specific tools. NOTICE: Due to the requirements dictated by the application, some assemblies may be located in different positions of the engine. To be able to set up support CNHT 0911 to fasten the engine on the trestle and perform the overhaul, proceed as follows: Remove from the right-hand side: 1. Remove the oil filter (1) located in the oil cooler.

LAIL11TM1213B0A

NOTE: Collect and dispose of the engine oil in accordance with current legislation. Position the fluid collection container in an appropriate manner. 2. Disconnect the turbocharger lubricating oil drain tube (1): • Loosen the two bolts (2) on the bottom of the turbocharger. • Loosen the fixing bolt (3) from the tube to the block with the clamp (4). • Lastly, loosen the joint (5) from the block. Cover the ends of the tube and turbocharger outlet.

LAIL11TM0876A0A

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Engine - Engine and crankcase

3. Support the engine appropriately and install support CNHT 0911, using the existing fastening holes on the rear face (1).

LAIL11TM0877A0A

LAIL11TM0878A0A

LAIL11TM0879A0A

4. Connect the second support CNHT 0911 using the threaded holes (2) in the front part of the engine.

NOTE: The front support requires two M 20 x 1.5 x 50 mm bolts for fixing (3). 5. Lift the engine and place it on the rotary trestle.

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Engine - Engine and crankcase

Engine - Disassemble Prior operation: Place the engine on a support, following the procedures described in Engine - Place on stand (10.001). ATTENTION: Avoid engine oil coming into contact with skin: if it does, wash the affected area in running water. NOTE: The engine oil is highly polluting, collect and dispose of the engine oil in accordance with current legislation. 1. Drain the lubricating oil from the engine via the sump drain plug. 2. Remove the thermostat body following the procedure ( Coolant thermostat - Remove (10.400)) 3. Remove the turbo compressor following the procedure ( Turbocharger - Remove (10.250) ) 4. Remove the fuel filter following the procedure Fuel filters - Remove (10.206). 5. To disconnect the low pressure tubes from the fastenings, press the clips (1) as shown in (A) . After disconnecting the tube, position the clip (1) in the (B) position so it locks.

LAIL11TM0892A0A

LAIL11TM0893A0A

6. Disconnect the LDA tube (1) from the head and injection pump. Place plugs in the tube ends, head and injection pump. 7. Remove the tubes from the injector pump and the injector nozzles. See procedure Injector fuel lines - Remove (10.218) 8. Remove the injector nozzles following the procedure described in Fuel injectors Mechanical - Remove (10.218) 9. Remove the fuel transfer pump. See procedure Fuel lift pump Diaphragm fuel pump - Remove (10.210)

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Engine - Engine and crankcase

10. Remove the valve covers: loosen the fastening bolts (1) and lift the covers (2). Retrieve the seals. NOTICE: In the illustration, the front cover has already been removed. The central cover contains a breather valve for the lubricant oil vapours (blow-by). All the gaskets must be replaced during assembly.

LAIL11TM1214B0A

LAIL11TM0898A0A

LAIL11TM0899A0A

11. To remove the intake manifold: loosen the eight fastening bolts (1) from the intake manifold to the head (two of them have been removed since they hold the injection nozzle pressure tube supports).

12. To remove the rocker arm sets: loosen the two fastening bolts (2) and remove the rocker arm set. Extract the valve rods. Repeat this operation for all rocker arm sets. 13. Remove the coolant temperature sensor (1).

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Engine - Engine and crankcase

14. Use a ratchet with a 1/2 in fitting to slacken the tensioner (1) tension and remove the drive belt (2). NOTE: The belt is longer on tractors fitted with air conditioning.

LAIL11TM0900A0A

LAIL11TM0901A0A

LAIL11TM0903A0A

15. Loosen the bolts (2) and remove the oil filter head (1) from the cylinder block. Remove the seals and oil cooler. 16. To remove the alternator, see the procedures described in Alternator - Remove (55.301). .

17. Loosen fastening bolts (1) from the coolant liquid inlet connector (2).

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Engine - Engine and crankcase

18. Remove the intermediate pulley (1) from the front of the engine. 19. Loosen the four bolts (2) and remove the pulley (3). 20. Loosen the bolt (4) and remove the tensioner (5). 21. Loosen the bolt (6) and remove the tensioner support (5). 22. Loosen the bolts (8) and remove the cylinder block base (7). 23. Loosen the bolts (10) and remove the water pump (9) from the cylinder block.

LAIL11TM1215B0A

24. Loosen the fastening bolts (1) and (2) from the cylinder head (3). 25. Pass steel cables around the supports and use a block and tackle to remove the cylinder head from the cylinder block. 26. Remove the gasket (4) from the cylinder block. 27. To remove the valve assembly, proceed as in Valves - Disassemble (10.101).

BRAG12TR0033LUE

LAIL11TM0908A0A

28. In the engine, install the crankshaft retention and turning tool, 380000988 (1) to prevent the engine flywheel turning 29. Loosen the fixing bolts from the engine flywheel to the crankshaft.

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Engine - Engine and crankcase

30. Loosen the bolts (1) and remove the pulley (2). 31. To remove and install the crankshaft front seal, follow the procedures in Crankshaft oil seal Front seal Disassemble (10.103).

LAIL11TM0909A0A

LAIL11TM0912A0A

LAIL11TM0913A0A

LAIL11TM0914A0A

32. Remove the bolts (1) and remove the oil pump (2). NOTE: Note the bolt assembly position (1), as they are of different lengths.

33. Remove two diametrically opposite bolts (1) where the extractor pins will be installed. 34. Loosen the other flywheel fastening bolts (3) on the crankshaft (2). 35. Remove the engine flywheel blocking tool (4).

36. Place two suitable length bolts in the holes (4) to support the engine flywheel with a block and tackle. 37. Using the two guide pins (2) previously installed in the crankshaft holes (3), guide extraction of the engine flywheel (1) with the aid of a block and tackle.

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Engine - Engine and crankcase

38. Fit tool (3) CNHT 0909 to the rear end of the crankshaft. 39. Drill the seal with a 3.0 mm bit.

LAIL11TM0915A0A

LAIL11TM0916A0A

BRAG12TR0044LUE

BRAG12TR0036LUE

40. Attach the tool (3) CNHT 0909 to the seal using the six bolts supplied (4). 41. Extract the seal by turning the bolt (2) clockwise.

42. Turn the engine upside down. 43. Loosen the bolts (2) and remove the engine oil sump (1). 44. Loosen the fixing bolts on the housing for the timing gears. Remove the housing for the timing gears from the cylinder block.

45. Using the pin (1), secure the additional masses (2) to the TDC. Remove the bolts (3) that secure the additional masses. Remove the additional masses.

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Engine - Engine and crankcase

46. Loosen the bolts (1) and remove the gear (3) from the camshaft (2).

LAIL11TM0918A0A

LAIL11TM0919A0A

LAIL11TM0920A0A

LAIL11TM0921A0A

47. Loosen the fastening bolts (1) from the conrod cover (2) and remove them. NOTE: Mark the covers to ensure that they will be installed in the same connection rods in which they were originally installed. 48. Extract the pistons together with the connection rods through the top of the cylinder block. NOTICE: Keep the shells in their respective housings because, if they are to be reused, they must be assembled in the same position in which they were found during disassembly. 49. Loosen the bolts (1) and remove the main bushing covers (2).

50. The cover of the penultimate main bushing (1) and its bushing have a shell (2) with a side thrust. NOTICE: Mark the back of the shell, block and cover assembly positions because, to be reused, they must be assembled in the same position in which they were found during disassembly.

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Engine - Engine and crankcase

51. Use suitable hooks to lift and remove the crankshaft (2) from the cylinder block. NOTICE: Never remove the flange and crankshaft gear, which are assembled with interference, without a key.

BRAG12TR0080LUE

LAIL11TM0923A0A

BRAG12TR0048LUE

BRAG12TR0049LUE

52. Remove the main shells (1); remove the bolts (2) and remove the oil ejectors (3).

53. Loosen the bolts (1) and remove the retention plate (2) from the camshaft (3). NOTICE: Note the assembly position for the plate (2).

54. Carefully extract the camshaft (1) from the cylinder block.

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Engine - Engine and crankcase

55. Extract the tappets (1) from the cylinder block.

LAIL11TM0926A0A

Next operation: To install the engine, see the procedures described in Engine - Assemble (10.001).

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Engine - Engine and crankcase

Engine - Assemble 1. Start the motor installation procedure by fitting the tappets and camshafts, following the procedures in Camshaft - Assemble (10.106). 2. Fit the oil spray nozzles in the cylinder as described in Piston cooling Spray nozzle - Assemble (10.304). 3. Fit the main bushings following the procedures in Crankshaft Journal - Assemble (10.103). 4. Install the crankshaft in the engine following the procedures in Crankshaft - Assemble (10.103). 5. Fit the main bushing caps as described in Main bearings - Assemble (10.103). 6. Fit the piston/conrod set, following the procedure in Connecting rod and piston - Assemble (10.105). 7. Install the piston rings as described in Piston Ring Assemble (10.105). 8. Fit the conrod bushes as described in Piston pin bushings - Assemble (10.105). 9. Fit the piston/conrod set in the cylinder sleeves, as described in Connecting rod and piston - Assemble the cylinder assembly (10.105). 10. Fit the conrod caps as described in Connecting rod bearing - Assemble (10.105). 11. Adjust the synchronisation of the synchronisation gears following the procedures in Crankcase gears - Timing adjust (10.114). 12. Fit the engine front cover as described in Engine block cover Front - Assemble (10.102). 13. Install the water pump as described in Water pump Install (10.400). 14. Install the oil pump as described in Engine oil pump - Install (10.304). 15. Replace the sump packing gland and fit it following the procedures described in Engine oil pan - Assemble (10.102). 16. Fit the engine flywheel following the procedures described in Engine flywheel - Assemble (10.103). 17. Fit the oil filter heads as described in Engine oil filter - Assemble (10.304). 18. Install the alternator following the procedures described in Alternator - Install (55.301) . 19. Fit the cylinder head as described in Cylinder head Assemble (10.101). Install the cylinder head following the procedures described in Cylinder head - Install (10.101). 20. Fit the rocker arm assembly as described in Rocker arm - Assemble (10.106). 21. Fit the injection nozzles as described in Fuel injectors Mechanical - Assemble (10.218).

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Engine - Engine and crankcase

22. Fit the valve seals as described in Valves Seal - Assemble (10.101). 23. Fit the exhaust manifold as described in Exhaust manifold - Assemble (10.254). 24. Fit the thermostat as described in Coolant thermostat - Assemble (10.400). 25. Fit the fan pulley as described in Idler pulley - Assemble (10.414). 26. Fit the alternator belt as described in Belt - Assemble (10.414). 27. Fit the intake manifold as described in Intake manifold - Assemble (10.254). 28. Install the feed pump as described in Fuel lift pump Diaphragm fuel pump - Install (10.210). 29. Fit the high pressure tubes as described in Injector fuel lines - Install (10.218). 30. Install the fuel filter as described in Fuel filters - Install (10.206). 31. Install the turbocharger as described in Turbocharger - Install (10.250). 32. Install the oil filter (1) on the support (2).

LAIL11TM0994A0A

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Engine - Engine and crankcase

33. Install the turbocharger lubrication return tube (1). • Tighten the two bolts underneath the turbocharger. • Fasten fixing bolt (2) from the tube to the block with the clamp (3). • Finally, connect the joint (4) to the cylinder block.

LAIL11TM1218B0A

LAIL11TM0995A0A

34. Install the starter motor (2) and, supporting it appropriately, tighten the fixing bolts (1) to the specified torque value.

35. To complete engine assembly it has to be removed from the swivel stand, as described in Engine - Install in tractor (10.001)

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Engine - Engine and crankcase

Engine - Install in tractor Prior operation: To install the engine, see the procedures described in Engine - Assemble (10.001). Before installing the engine in the tractor, consider to the following points: 1. Ensure that all fixing bolts are tightened to the correct torque, following Engine - Torque (10.001) 2. After installation, check that all the fluid and lubricant levels are correct. Start the engine and let it run until it reaches the correct operating temperature to purge the air from the cooling system. Stop the engine, check for leaks, repair if necessary and recheck the various levels.

LAIL11TM1280A0A

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Engine - Engine and crankcase

Engine - Compression test 1. Ensure that the battery is well charged. 2. Start the engine and leave it running until the temperature displayed on the instrument panel stabilizes. 3. Shut down the engine. Remove all injection nozzles. NOTE: Remove all injection nozzles to allow the engine to turn. 4. Clean the inside diameter of the cylinder nozzles to be tested. Turn the engine to expel any carbon particles that may be loose in the combustion chamber. 5. Shut down the injection pump coil's electric power. 6. Install the adapter ( 380000617) in place of the injection nozzle. Use the injector mounting bolts and a seat washer. Place a compression gauge ( OEM1074) on the adapter 7. Turn the ignition key and run the engine until rotation reaches approximately 200 RPM. Take the cylinder compression reading. 8. Repeat steps 5 and 6 for all injection nozzles. Record compression values in Table 1. 9. Perform steps 5 and 6 adding a spoonful of engine lubricant oil to the combustion chamber. Record compression values in Table 1. NOTE: The rate of compression must be in line with the value and tolerances provided as part of the engine specifications ( Engine - General specification (10.001)).

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Engine - Engine and crankcase

Table

Table 1: Table for recording the engine compression test Person Responsible: Customer Name: Chassis Code: Engine #:

Date: City: Model: Hour meter (hours): API Classification:

Brand of Lubricant Oil: Without oil in the combustion chamber Mark the pressure gauge unit of measurement: Compression Cylinder 1 Cylinder 2

bar (___) Cylinder 3

Cylinder 4

psi (___) Cylinder 5

Cylinder 6

With oil in the combustion chamber Mark the pressure gauge unit of measurement: Compression Cylinder 1 Cylinder 2

bar (___) Cylinder 3

Cylinder 4

psi (___) Cylinder 5

Cylinder 6

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Engine - Engine and crankcase

Crankcase Liner - Replace Replacing the cylinder block bushes To replace the front bush (1), use a suitable rod to remove and install it. NOTE: During installation, the bush (1) must be directed so that the lubrication holes match the holes in their housing in the cylinder block.

BRAG12TR0082LUE

Next operation: Installation of camshaft, check the procedures in Camshaft - Assemble (10.106).

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Engine - Engine and crankcase

Crankcase - Backlash Checking and measuring 1. After disassembling the engine, thoroughly clean the cylinder block. Use appropriate rings to transport the cylinder block. 2. Check carefully for cracks in the cylinder block. 3. Check the conditions of the plugs and the mechanical seals. If they are rusty or their sealing is doubtful, replace them. 4. Examine the cylinder sleeve surfaces: they must not present signs of widening, galling, ovalization, conicity or excessive wear. 5. To check the internal diameter of the cylinder heads for ovalization, conicity or wear, use a sudden (1), equipped with a calibration gauge zeroed on a standard ring (2) the same diameter as the cylinder sleeve.

LAIL11TM0996A0A

LAIL11TM0997A0A

NOTICE: If no standard ring is available, use a micro meter. 6. Measurements must be taken for each cylinder sleeve at three different heights and on two orthogonal faces: one parallel to the engine's axis and the other perpendicular; maximum wear is generally found on this face, corresponding to the first measurement. 7. If ovalization, conicity or general wear are noticed, polish and overhaul the cylinder sleeves. The cylinder sleeves must be rectified according to the diameter of the pistons supplied as spare part with an oversize of 0.5 mm above the rated measurement and the dimensions specified for assembly. NOTICE: In case of servicing, all the cylinder sleeves must have the same oversize of 0.5 mm.

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Engine - Engine and crankcase

8. Check the main bushing seats proceeding as follows. • Install the main bushing covers on the housings without the shells. • Tighten the fixing bolts to the specified torque value. • Use an appropriate calibration gauge for internal diameters, check if the seat diameters are according to specification. If the measurement result is higher, replace the cylinder block.

LAIL11TM1219B0A

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Engine - Engine and crankcase

Engine - Troubleshooting Problem The engine does not run or has difficulty in working

Engine loses speed or runs irregularly

Possible Cause Incorrect starting process.

Correction Review the starting process

Low or no fuel. Air in fuel piping. Low ambient temperature. Contaminated fuel system. Fuel pump not operating. Fuel filter(s) clogged. Failure in fuel injectors. Failure in fuel solenoid or solenoid relay. Engine oil viscosity incorrect. Incorrect fuel for working temperature.

Check fuel level. Bleed fuel system. Use cold start. Clean and bleed fuel system. Check fuses. If good, replace the pump. Replace the fuel filter element(s). Install new parts and check their operation. Install new parts and check their operation. Use oil with the correct viscosity. Use the correct type of fuel for the temperature conditions. See the starting speed in the Electrical part. Replace the fuel filter element(s). Clean and bleed the fuel system

Low starting speed. Fuel filter(s) clogged. Contaminated fuel system Fuel solenoid adjusted incorrectly

Engine without power

Engine knocking

Engine overheating.

Adjust the solenoid valve to the recommended specifications Fuel cover breather blocked Clean the cover breather in clean diesel Reduce: gear, load, ballast Overloaded engine Blocked or dirty air filter Clean air filter Engine working temperature too low Check thermostats Engine overheating. Investigate the causes of engine overheating Fuel filters blocked or saturated Replace the fuel filter element(s) Incorrect fuel Use the correct type of fuel Engine valve clearances incorrect Check and adjust Install new parts and check their operation. Failure in fuel injectors Install new parts and check their operation. Failure in fuel injection pump Send the injection pump to a manufacturerauthorised dealer to identify the fault. Maximum unloaded speed too low Adjust the engine speed maximum limit. Air leakage in intake and exhaust manifolds Check the air pipes and manifold to identify and eliminate air leaks Install new parts and check their operation. Turbocharger failure (if installed) Send the injection pump to a manufacturerauthorised dealer to identify the fault. Poorly adjusted implement Adjust the implement in line with manufacturer's guidelines. Injection pump synchronism Check and correct synchronisation of injection pump Engine oil level is low Top up the engine lubricating oil Engine oil pressure low Check for blocked lines and possible damage to engine oil pump. Engine working temperature low Check thermostats Engine overheating. — Check seal inside the hood: — Obstruction in screen for hood and radiator; — Check that the implement is compatible with the machine's net power; — Check that the level of coolant and the thermostatic valve are correct; Engine oil level low. Add oil as necessary. Engine coolant level low. Fill coolant expansion tank. Check for leaks in the cooling system. Faulty thermostat(s). Check thermostat(s). 73403953 04/04/2014

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Engine - Engine and crankcase

Problem

Low engine operating temperature Low engine oil pressure

Excessive engine oil consumption

Possible Cause Radiator core either dirty or blocked. Excessive engine overload. Defective radiator pressure cap. Blocked cooling system. Engine fan belt loose or worn. Leaking from hoses or joints. Defective thermostat or indicator. Damaged thermostat(s) Oil level low Incorrect oil grade or viscosity Engine oil level too high Incorrect oil grade or viscosity Sump vent filter tube blocked Turbocharger failure (if installed)

Excessive fuel consumption

Oil leakage Valve guides and seals worn Low engine working temperature.

Correction Clean. Reduce: gear, load, ballast. Replace the radiator cap. Wash cooling system. Check automatic tensor, replace belt if worn. Fasten joints and/or replace hoses. Consult your New Holland Dealer. Replaced thermostat(s) Add oil as necessary Drain and fill with oil of the correct specification Reduce the oil level as necessary Drain and fill with oil of the correct specification Replace vent filter Install new parts and check their operation. Send the injection pump to a manufacturer approved dealer to identify the fault. Repair leaks Install new parts and check their operation. See low engine working temperature.

Install new parts and check their operation. Send the injection pump to a manufacturerauthorised dealer to identify the fault. Engine overloaded. Reduce: gear, load, ballast. Blocked air filter. Clean air filter. Incorrect fuel. Drain all the fuel from the fuel tank and the engine feed lines. Fill the fuel tank with quality fuel that meets the manufacturer's specifications. Engine valve clearances incorrect. Check and adjust. Install new parts and check their operation. Damaged fuel injectors. Damaged injection pump. Install new parts and check their operation. Send the injection pump to a manufacturerauthorised dealer to identify the fault. Air leakage in intake and exhaust mani- Check the air pipes and manifold to identify folds. and eliminate air leaks Poorly adjusted implement. Adjust the implement in line with manufacturer's guidelines. bolt. Turbocharger failure (if installed).

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Index Engine - 10 Engine and crankcase - 001 Crankcase - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Crankcase Liner - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Engine - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Engine - Compression test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Engine - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Engine - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine - Install in tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Engine - Place on stand . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine - Remove the engine from the transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

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Engine - 10 Pan and covers - 102

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Pan and covers - 102

SERVICE Engine oil pan Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine block cover Front - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 73403953 04/04/2014

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CONSUMABLES INDEX Consumable Loctite® 5205 Loctite® 5205

Reference Engine block cover Front - Assemble Engine block cover Front - Assemble

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PAGE 10.2 / 5 10.2 / 5

Engine - Pan and covers

Engine oil pan - Assemble 7630 8030

LA LA

Prior operation: To install the oil pump, see Engine oil pump - Install (10.304).

Tightening sequence 1. Tightening sequence for engine sump bolts.

BRAG12TR0030LUE

LAIL11TM0961A0A

LAIL11TM0962A0A

2. Before installing the engine sump, put a new gasket (1) on the cylinder block (2).

Installing the engine oil sump 3. Install the sump (1) and tighten the bolts (2) to the specified torque value. NOTICE: Before each assembly, always check whether the hole and bolt threads show wear or traces of dirt.

Next operation: To install the engine flywheel, see Engine flywheel - Assemble (10.103).

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Engine - Pan and covers

Engine block cover Front - Assemble Prior operation: For synchronisation of the synchronisation gears, see procedures in Crankcase gears - Timing adjust (10.114). Diagram of the area to apply the sealant LOCTITE® 5205 on the front cover. 1. Carefully clean the adapter plate and the cylinder block. NOTICE: It is necessary and indispensable to clean the sealing surfaces for an effective seal. Apply LOCTITE® 5205 sealant to the box to form a thread (1) a few millimetres in diameter. It must be even, without any lumps, air bubbles, thinning or ruptures. Any fault must be corrected in the shortest possible time. Avoid using excess material to form the joint. Too much sealant tends to ooze from the sides of the joint obstructing the passage of lubricant. After applying the sealant, bond the parts immediately ( 10 20 min).

LAIL11TM0951A0A

LAIL11TM0952A0A

LAIL11TM0956A0A

Sequence for tightening the front cover bolts 2. Install the synchronism gear box (1) on the cylinder block. 3. Place two fixing bolts (2) to fasten the synchronism gearbox (1). 4. Use a torque meter to tighten the bolts ( (2) - (3)) to the specified torque value in a crossed sequence. • M8 bolts – 20 - 28 N·m • M10 bolts – 42 - 52 N·m NOTICE: Before each assembly, always check whether the hole and bolt threads show wear or traces of dirt. 5. Install the rear retainer onto the crankshaft flange. Install tool CNHT 0909 and tighten the central spindle anti-clockwise until the tool touches the cover.

Next operation: For installation of the water pump, see Water pump - Install (10.400)

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Index Engine - 10 Pan and covers - 102 Engine block cover Front - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pan - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Valve drive and gears - 106

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Rocker shaft Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Camshaft Tappets - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Camshaft bushings Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Valve drive and gears Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Repair and grinding the seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Rocker arm Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Camshaft Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Camshaft bushings Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Rocker shaft - Dimension 1. Check the support and rocker arm shaft contacts surfaces: there should not be any signs of damage or excess wear. Replace damaged or worn parts as needed.

LAIL11TM1036A0A

1. Rocker arm adjustment bolt data.

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LAIL11TM1037A0A

Tighten the nuts (1) to a torque of 0.25 - 0.75 NÂˇm.

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Camshaft Tappets - Dimension

BRAG11TR0127LUE

Main data of the tappets and their respective seats on the block (in mm)

Camshaft - Dimension

BRAG11TR0150LUE

The data refers to the normal diameter (in mm) of the trunnions. A. Inlet valve cam S. Exhaust valve cam The support trunnion and cam surfaces must be finely overhauled. If there are scratches or galling replace the shaft and respective bushes.

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Camshaft bushings - Dimension

BRAG11TR0149LUE

Data for camshaft bushes and intermediate supports * The size is obtained after installing the lubrication box (in mm).

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Valve drive and gears - Alignment Checking lifting and alignment 1. Position the camshaft between the ends and use a calibration gauge with a 1/100 mm, scale positioning on the central support check if the misalignment is no larger than 0.04 mm. Replace the shaft if this occurs. Check cam lifting: it should be 6.045 mm for exhaust cams and 7.582 mm for intake cams. Replace the shaft if the measures differ from these. 2. Check the diameter of the camshaft support trunnions (2) with a micrometer (1) at two perpendicular axis. Consult the procedures in Camshaft - Dimension (10.106). LAIL11TM1005A0A

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Valve drive and gears - Repair and grinding the seats Seat overhaul â&#x20AC;&#x201C; replacement 1. Check the valve seats (2). If you find any light abrasions or burns, grind the valve seats using a valve grinder (1), according to the angles indicated in Valve cover Rocker housing - Dimension (10.101). 2. If the valve seats cannot be reconditioned just by overhauling, they can be replaced with parts supplied as spare parts. Use the same tool from the previous figure and take care not to cut the cylinder head to remove as much material as possible from the valve seat until it is possible to extract it from the head with the aid of a punch. LAIL11TM1033A0A

LAIL11TM1034A0A

3. Heat the head to between 80 - 100 Â°C and using a suitable tool install the new, previously cooled, valve seats. 4. Use a suitable tool to grind the valve seats according to the values given in Valve cover Rocker housing Dimension (10.101). 5. After overhauling, check with a calibration gauge (1) on a magnetic base (2), if the valve recess (3) is as specified.

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Rocker arm - Assemble Prior operation: To install the cylinder head, see Cylinder head - Install (10.101). 1. Install the rocker arm assemblies after checking the parts. The parts that comprise the rocker arm set are: 1.

Lock ring

Spacer

Rocker

Support

LAIL11TM0976A0A

LAIL11TM0977A0A

LAIL11FA0936A0A

2. Before installation, check the valve rods: they should not have deformities; should not present signs of scraping or wear on the contact surfaces with the spherical seats on the rocker arm or tappet adjustment bolts (arrows). If any of the above items occur, replace the rods. 3. The intake and exhaust valve rods are identical and can be interchanged.

4. Insert the valves and the rocker arm assemblies. Before reusing the fixing bolts, take two measurements of the diameter as shown in Fig. 3, measuring diameters D1 and D2: • If D1 – D2 < 0.1 mm, the bolt can be reused. • If D1 – D2 > 0.1 mm, the bolt must be replaced.

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5. Tighten the bolts (2) to the specified torque value and install the coolant temperature sensor (1).

LAIL11TM0979A0A

Next operation: For installation of the injector nozzles, see Fuel injectors Mechanical - Assemble (10.218).

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Camshaft - Assemble Prior operation: Cylinder block sleeve replacement, check Crankcase Liner - Replace (10.001). 1. Before installing the tappets, check their dimensions against the standard dimensions shown in Camshaft Tappets - Dimension (10.106). 2. Lubricate the tappets (1) and position them in their housings in the cylinder block.

BRAG12TR0085LUE

BRAG12TR0086LUE

BRAG12TR0087LUE

3. Lubricate the camshaft support bushings (1), being careful that they that they are not damaged during shaft assembly.

4. Position the plate (1) that retains the camshaft (3) with the groove facing the top of the cylinder block and the punched marking facing the operator. Tighten the bolts (2) to the specified torque value.

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5. Check the axial clearance for the camshaft (1); it should be 0.10 - 0.36 mm.

BRAG12TR0088LUE

Next operation: Installing oil spray nozzles Piston cooling Spray nozzle - Assemble (10.304)

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Camshaft bushings - Measure Bushings 1. The camshaft bushes (2) must be installed by being forced into their respective housings. 2. The internal surfaces must not show signs of scratches or wear. 3. Use a hole gauge (1) to measure the diameter of the front and rear bushes (2) and the camshaft intermediate supports. 4. The measurements must be made at two perpendicular axis. 5. Check the permitted measurements for the bushes in Camshaft bushings - Dimension (10.106). BRAG12TR0084LUE

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Index Engine - 10 Valve drive and gears - 106 Camshaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Camshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Camshaft Tappets - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Camshaft bushings - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Camshaft bushings - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rocker arm - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rocker shaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve drive and gears - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Valve drive and gears - Repair and grinding the seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - 10 Cylinder heads - 101

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Valve cover Rocker housing - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Valves Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Valve guide Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Cylinder head Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check contact surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Valves Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust of the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Seal - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Backlash between the rod and the valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Engine - Cylinder heads

Valve cover Rocker housing - Dimension

A B

BRAG11TR0132LUE

BRAG11TR0133LUE

Unload Valve Intake valve

W gate Intake valve

If the valve housings cannot be restored only by resurfacing them, you can replace them as spare parts. Remove the largest possible amount of material from the valve housings to be replaced, paying attention to not reach the poppet. Remove the remains with a punch. Heat the poppet to 80 - 100 Â°C with an appropriate device. Install the new properly cooled seats. Then grind the new housings according to the values stated in the figure.

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Valves - Dimension Inlet and exhaust valve data.

BRAG11TR0130LUE

Valves Spring - Dimension Before assembly, check the valve spring flexibility. Compare the elastic deformation and load data with those of new springs.

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LAIL11TM1035A0A

Height 63.50 mm H (Free) 49.02 mm (H1) 39.20 mm (H2)

Load 0N 329 N (P1) 641 N (P2)

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Valve guide - Dimension 1. Use a gauge to measure the valve guide internal diameter. It should be as shown in Figure 1.

BRAG11TR0131LUE

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Cylinder head - Assemble Prior operation: To install the alternator, see the procedures in Alternator - Install (55.301). 1. Before installing the head, check its contact surface as described in Cylinder head - Check contact surface (10.101). 2. Lubricate the valve rods (1) and insert them in their guides according to the positions marked during disassembly. 3. Install the seals (2) and (3) in the valve guides. NOTICE: The seals (2) for the intake valves are yellow and the seals (3) for the exhaust valves are green.

LAIL11TM0971A0A

LAIL11TM0972A0A

4. Position the following parts on the cylinder head: protective cap (5), spring (4) and disk (3). Use a tool to compress the spring (4) and lock the parts in the valve (6) with the locks (2). NOTE: Before assembly, check the valve spring flexibility. Compare the elastic deformation and load data with those of new springs.

Next operation: To install the cylinder head, see Cylinder head - Install (10.101).

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Cylinder head - Install Prior operation: To install the cylinder head, see Cylinder head - Assemble (10.101). 1. Also run the leak test following the procedure in Cylinder head - Leakage test (10.101). 2. Position the head gasket (1) with the word "TOP" facing the head. NOTICE: Check if the cylinder block surface is clean. Do not grease the gasket. It is recommended to keep the gasket in its package until the head is installed. NOTE: The gasket thickness must be selected as a function of the measurement of piston projection over the cylinder block face. The gasket is available in two thicknesses: 1.15 mm and 1.25 mm. Select the correct gasket according to the dimension of the piston projection. • Piston projection up to 0.35 mm, use a 1.15 mm gasket. • Piston projection of 0.35 mm above, use a 1.25 mm gasket. The arrow indicates the point where the gasket thickness is shown.

LAIL11TM0973A0A

BRAG12TR0033LUE

BRAG11TR0134LUE

3. Place the head (3) on the cylinder block and insert the bolts (1) and (2). NOTICE: In case the valves were removed from the head, they must be installed before installing the head on the engine cylinder block. Before installation, check the head for leak-proof sealing.

4. Lubricate the bolts and install them in the cylinder head block. NOTICE: Before reusing the cylinder head fixing bolts, check them for signs of deterioration or deformation. If they show signs of deterioration or deformation, replace the bolts. If D1 – D2 < 0.1 mm, the bolt can be reused. If D1 – D2 > 0.1 mm, the bolt must be replaced.

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5. The bolts must be tightened following an elongation pattern, starting from the central bolts toward the outside ones. 1st Step - tightening with torquemeter: • Bolt M12 x 1,75 x 70: (ref. 3-6-11-14): 50 N·m • Bolt M12 x 1.75 x 140: (ref. 1-2-7-8-9-10-15-16-1718): 40 N·m • Bolt M12 x 1.75 x 180: (ref. 4-5-12-13): 70 N·m 2nd Step - tightening with a 90º angle on all bolts. 3rd Step - additional tightening with a 90º angle only for 140 - 180 mm bolts. A = Fan side Next operation: To install the rocker arm assembly, see Rocker arm - Assemble (10.106).

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BRAG11TR0158LUE

Engine - Cylinder heads

Cylinder head - Check contact surface 1. After locating any deformity on the contact surface, flatten it. 2. Level differences should not exceed 0.075 mm. Check the conditions of the cylinder block plugs. If they are rusty or their sealing is doubtful, replace them.

Checking the cylinder head contact surface 3. The maximum deformation measured along the full length of the head cannot be greater than 0.20 mm. 4. If it is larger, overhaul the cylinder head according to the dimensions and specifications provided below and in the illustration on the side. 5. The cylinder head nominal thickness "A" is 94.75 95.25 mm. The maximum allowed for material removal cannot exceed thickness B of 0.13 mm. NOTICE: After rectifying, check the valve recesses. If necessary, overhaul the valve seats to obtain the specified recesses. LAIL11TM1027A0A

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Cylinder head - Leakage test 1. Check tightness using appropriate tools. 2. Use a pump to introduce water heated to approximately 90 Â°C, at a pressure of 2 - 3 bar. 3. If there are any leaks through the mechanical seals (1), replace them using a suitable tool for their removal and installation. NOTICE: Before installing the plugs, apply water reagent seal on the sealing surfaces. 4. If there are any leaks on the cylinder head it must be replaced. BRAG12TR0083LUE

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Valves - Disassemble Prior operation: Proceed as in Engine - Disassemble (10.001) up to step 26. 1. The intake (1) and exhaust (2) valve heads have different diameters. NOTICE: Before removing the valves from the cylinder head, number them so that they are installed in the same positions if they are not to be replaced. A = intake side

LAIL11TM0905A0A

LAIL11TM0906A0A

LAIL11TM0907A0A

2. The valves are removed using a general tool to compress the valve springs (1). Apply pressure on the disk (3), and by compressing the spring (4), it is possible to remove the locks (2). Remove the disk (3) and the spring (4). 3. Repeat this operation for all valves. 4. Turn the head and remove the valves (5).

5. Remove the seals (1) and (2) from the valve guides. NOTICE: The seals (1) for the intake valves are yellow. The seals (2) for the exhaust valves are green. To install the valves and the poppet, see the procedures in Cylinder head - Assemble (10.101).

Next operation: Head integrity test, see the procedures in Cylinder head - Leakage test (10.101).

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Valves - Adjust of the gap NOTE: Checking and adjustment are only done after installing the head on the cylinder block and installation of the camshaft. 1. Adjust the clearance between the rocker arms and the valves with an Allen wrench (1), closed end spanner (3) and feeler gauge (2). Working clearance must be: • Intake valves 0.20 - 0.30 mm • Exhaust valves 0.46 - 0.56 mm 2. To adjust valve clearance more quickly, proceed as follows: • Turn the engine by balancing the valves in cylinder No. 1 and adjust the valves marked with an X, as indicated in the table: Cylinder No. Intake Exhaust

1 -

2 X -

LAIL11TM1038A0A

3 X -

4 X X

3 X

4 -

• Turn the engine by balancing the valves in cylinder No. 4 and adjust the valves marked with an X, as indicated in the table: Cylinder No. Intake Exhaust

1 X X

2 X

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Valves Seal - Assemble Prior operation: For installation of the injector nozzles, see Fuel injectors Mechanical - Assemble (10.218). 1. Install the valve covers (2) with their respective seals. Insert the sealing plugs and tighten the bolts (1) to the specified torque value. NOTICE: Always use new gaskets. Check the threads of the fixing bolts: they should not show signs of wear or traces of dirt. The sealing plugs must not show obvious signs of deformation. Replace those that show deformation.

LAIL11TM1216B0A

Next operation: To install the exhaust manifold, see Exhaust manifold - Assemble (10.254).

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Engine - Cylinder heads

Valves - Repair 1. Remove all the carbon deposited on the valves with a steel brush. 2. Check the valves for signs of scratches, cracks or burns. 3. If needed, overhaul the valve seats removing the minimum material possible.

LAIL11TM1029A0A

LAIL11TM1030A0A

4. Use a micrometer (2) to measure the valve rod (1). It should be 7.960 - 7.980 mm. 5. Consult the standard valve dimensions in Valves - Dimension (10.101) 6. Check the clearance between the rod and the valve guides following the procedures described in Valves - Backlash between the rod and the valve guide (10.101)

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Engine - Cylinder heads

Valves - Backlash between the rod and the valve guide 1. Checks are made with a calibration gauge (1) on a magnetic base positioned as in the illustration. The assemble clearance is 0.052 - 0.092 mm. 2. Turn the valve (2) to make sure the centring error is no more than 0.03 mm.

LAIL11TM1031A0A

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Index Engine - 10 Cylinder heads - 101 Cylinder head - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Cylinder head - Check contact surface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Cylinder head - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cylinder head - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Valve cover Rocker housing - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Valve guide - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Valves - Adjust of the gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Valves - Backlash between the rod and the valve guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Valves - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Valves - Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Valves Seal - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Valves Spring - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - 10 Connecting rods and pistons - 105

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rod and piston Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Connecting rod and piston Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Connecting rod and piston Connecting rod - Test twisting and warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble the cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Check cylinder assembly projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Piston Ring - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Ring - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Connecting rod bearing Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Backlash of the connecting rod journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Piston pin bushings Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Connecting rod and piston - Dimension Link conrod, piston pin bush and shell data

BRAG11TR0129LUE

* Internal diameter to be measured after installation in the link conrod with enlarger. ** Can not be measured free NOTE: The link conrod – link conrod cover contact surfaces are knurled for better coupling. Removal of this knurling is not recommended. The link conrods are produced with a cutting technique that makes each link conrod and cover unique, with one single way of assembling. Every link conrod is marked: 1. On the body and cover with a number to indicate its pairs and cylinder where it is mounted. In case of replacement, number the new link conrod with the same number as the replaced conrod. On the link conrod body with a letter to indicate the link conrod weight class assembled in production.V 1600 - 1640 g · W, 1641 - 1680 g · X, 1681 - 1720 g 73403953 04/04/2014

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LAIL11TM1221B0A

The link conrods are supplied as spare part in the W class and are marked green*. Material removal is not allowed.

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Piston

BRAG11TR0128LUE

Main data of the Mondial Mahle piston, two pins and of the piston rings (in mm)

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Connecting rod and piston - Exploded view Piston/link conrod assembly component parts.

BRAG12TRLUE0533

1 2 3 4

Locking ring Piston pin Picton Piston rings

Screw 5 6 Link conrod shells 7 Connecting Rod 8 Bushing

NOTE: The pistons are supplied as spare parts at an oversize of 0.5 mm.

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Connecting rod and piston Connecting rod - Test twisting and warping Bushings 1. Check the bushes and link conrods for signs of looseness, scratches or galling. If so, replace them. 2. Removal and installation are executed with an adequate tool. 3. During installation, make sure that the holes for lubrication on the bush and the link conrod match. Use an enlarger to rectify the bush and obtain the specified diameter.

Link conrod check 4. Check the conrod is parallel on its axis (1) using tool (5) 380001003 as follows: â&#x20AC;˘ Install the conrod (1) on the axle of tool (5) 380001003 and lock it with bolt (4). â&#x20AC;˘ Place the axle (3) on V-blocks adjusting the conrod (1) on the limiting bar (2).

LAIL11TM1017B0A

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Engine - Connecting rods and pistons

Torsion check 5. Check for conrod warping (5) by comparing two points (A) and (B) on pin (3) on the horizontal plane of the conrod axial shaft. 6. Position the support (1) for the calibration gauge (2) so there is a preload of approx. 0.5 mm on the pin (3), on point (A) and zero the gauge display (2). Move the axle (4) with the conrod (5) to the opposite side (B) of the pin (3). 7. Compare any deviation. The difference between (A) and (B) must not be greater than 0.08 mm.

LAIL11TM1018B0A

LAIL11TM1019B0A

Warp check 8. Check for conrod warping (5) by comparing two points(C) and (D) on pin (3) on the vertical plane of the link conrod axial axle. 9. Position the vertical support (1) of the calibration gauge (2) so that it sits on the pin (3) at point (C). 10. Turn the link conrod forward and backward observing the highest position of the pin and zero the gauge (2) in this condition. 11. Move the axle with the conrod (5) to the opposite side (D) of the pin (3). Repeat the check at the highest point. The difference between points (C) and (D) must not be greater than 0.08 mm.

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Engine - Connecting rods and pistons

Connecting rod and piston - Assemble Prior operation: For assembly of the main bushing caps, follow the procedures described in Main bearings - Assemble (10.103) 1. Before installing the piston/conrod assembly, measure the piston and check with the measurements given in Connecting rod and piston - Dimension (10.105). 2. The following references are stamped inside the piston crown: (1)Spare part number and project modification number. (2)Arrow indicating the direction in which to assemble the piston in the cylinder: should indicate the front of the cylinder block. (3)Date of manufacture. (4) Stamp indicating the 1st groove insert test.

LAIL11TM0939A0A

LAIL11TM0940A0A

LAIL11TM0941A0A

3. Using the pin (3), connect the piston (2) to the conrod (4), so that the reference arrow (1) for installing the piston (2) in the cylinder sleeve and the numbers (5) stamped in the conrod (4) are as shown in Figure 2.

4. Insert the lock rings (2) for the piston pin (1).

Next operation: For installation of piston rings, see Piston Ring - Assemble (10.105).

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Engine - Connecting rods and pistons

Connecting rod and piston - Assemble the cylinder assembly Prior operation: For installation of the conrod bushings, see Piston pin bushings - Assemble (10.105) 1. Thoroughly lubricate the pistons, including the rings and the inside of the cylinder sleeves. 2. With the aid of a ring belt (2), install the piston/conrod sets (1) in the cylinder sleeves, checking that: • The number of each link conrod cover matches its link conrod. 3. After installing the assembly in the cylinder sleeve, check the assembly protection following the procedures in Connecting rod and piston - Check cylinder assembly projection (10.105). LAIL11TM0944A0A

LAIL11TM0945A0A

Schema for installing the piston and conrod assemblies in the cylinder sleeves • The ring openings must be 120º out of phase. • The piston/link conrod sets must be all of the same class of weight. • The arrow (1) stamped on the piston crown must face the front of the cylinder block, or the recess on the piston skirt must match the position of the oil spray nozzles.

Next operation: For installation of the conrod caps, see Connecting rod bearing - Assemble (10.105).

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Engine - Connecting rods and pistons

Connecting rod and piston - Check cylinder assembly projection 1. After installing the piston/conrod assemblies, use a calibrator gauge (1) installed in a magnetic base (2).

LAIL11TM1025A0A

LAIL11TM0996A0A

2. Check piston projection (3), at TBD above the upper face of the cylinder block. It should be 0.28 - 0.52 mm.

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Engine - Connecting rods and pistons

Piston Ring - Disassemble 1. Remove the rings (1) from the piston (2) with suitable ring pliers (3) .

LAIL11TM1008A0A

LAIL11TM1009A0A

2. The lock rings (2) for the piston pins (1) must be removed using ring pliers or a punch (3).

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Piston Pin - Measure Piston pins 1. Measure the diameter of the piston pin (1) using a micrometer (2).

LAIL11TM1011A0A

LAIL11TM1010A0A

LAIL11TM1012A0A

Piston 1. Measure the piston diameter (1) using a micrometer (2) to determine the mounting clearance. NOTICE: The diameter must be measured at a distance of 12 mm from the piston skirt base.

2. The clearance between the piston and the cylinder sleeve is calculated as the difference between the piston diameter and cylinder sleeve diameter measurements.

Conditions for correct coupling of the piston pin 1. Lubricate the pin (1) and the bush in the piston with engine oil. The pin should enter the piston with slight finger pressure and should not fall out.

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Engine - Connecting rods and pistons

Piston Ring - Measure 1. Check the ring thickness (2) with a micro meter (1). • 1st Ring: 2.560 - 2.605 mm • 2nd Ring: 2.350 - 2.380 mm • 3rd Ring: 3.970 - 3.990 mm

LAIL11TM1013A0A

LAIL11TM1014A0A

LAIL11TM1015A0A

LAIL11TM1016A0A

2. Check the clearance between the rings (3) on the second and third piston grooves (2) with a feeler gauge (1). • Second ring clearance: 0.100 - 0.110 mm • Third ring clearance: 0.04 - 0.08 mm

Measuring X clearance between the first groove and the V ring 3. Due to the special shape of the first ring with a trapezoidal cross section, you must measure the clearance between the groove and the ring as follows: 4. Move the piston (1) out of the cylinder block so that approximately half of the thickness of the ring (2) extends out of the cylinder liner (3).

5. In this position, use a feeler gauge to check the clearance between the ring and the groove. The clearance should be between 0.245 - 0.265 mm. 6. Measure the clearance between the ends of the rings (2) introduced in the cylinder sleeve (3), using a feeler gauge (1). • 1st Ring: 0.30 - 0.40 mm • 2nd Ring: 0.60 - 0.80 mm • 3rd Ring: 0.30 - 0.80 mm

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Engine - Connecting rods and pistons

Piston Ring - Assemble Prior operation: For assembly of the piston/conrod set, see Piston Ring - Assemble (10.105) 1. Before installing the piston rings, check their measurements as described in Piston Ring - Measure (10.105). 2. To install the rings (1) on the piston (2), use suitable ring pliers (3). 3. The rings must be installed with the word â&#x20AC;&#x153;TOPâ&#x20AC;? facing upward and positioned so that their openings are 120Âş out of phase. NOTICE: Piston rings are supplied as spare parts in the following measurements: - Standard, marked with yellow paint; - 0.5 mm over-size and marked with yellow/green paint.

LAIL11TM0942A0A

Next operation: Installing the conrod bushings. as in Piston pin bushings - Assemble (10.105).

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Engine - Connecting rods and pistons

Connecting rod bearing - Assemble Prior operation: For installation of the piston/conrod assembly in the cylinder sleeve, see Connecting rod and piston - Assemble the cylinder assembly (10.105). 1. Tighten the bolts (1) pre-lubricated with engine oil, with a torque meter (2) to the torque specified value. • 1st Stage with torque meter 27 - 33 N·m. • 2nd Stage with torque meter 55 - 65 N·m. NOTE: To measure the conrod cap clearance, see the step procedure described in Connecting rod bearing - Backlash of the connecting rod journals (10.105).

LAIL11TM0946A0A

LAIL11TM0947A0A

2. Install an angle meter (1) on the ratchet and tighten the bolts (2) at an angle of 55 - 65 °.

Next operation: For synchronisation of the distribution gears, see the procedures in Crankcase gears - Timing adjust (10.114).

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Engine - Connecting rods and pistons

Connecting rod bearing - Backlash of the connecting rod journals To measure the clearance proceed as follows: 1. Carefully clean all the parts removing any traces of oil. 2. Position one segment of calibrated wire (2) on the link conrod trunnions (1). 3. Install the respective link conrod covers (3) with the shells (4).

LAIL11TM1020A0A

LAIL11TM1021A0A

LAIL11TM1022A0A

LAIL11TM1023A0A

4. Use a torque meter (2), to tighten the pre-lubricated bolts (1) to the specified torque value.

5. Install an angle meter (1) on the ratchet and tighten the bolts (2) at an angle of 60ยบ.

6. Remove the covers and determine the clearance between the shell and trunnion by comparing the width of the calibrated wire (1), at the point of greatest crushing with scale graduation (2). 7. If the clearance found is different from that specified, replace the shells and repeat the check.

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8. After obtaining the specified clearance lubricate the shells and install the link conrod covers tightening the fixing bolts to the specified torque value. NOTICE: Before definitively installing the link conrod cover fixing bolts, check that their diameters measured at the centre of the thread length are not less than 0.1 mm than the diameter measured approximately 10 mm from the bolt end. 9. Manually check the link conrod axial displacement (1), over the crankshaft trunnion. Measure with a feeler gauge (2). Axial clearance should be 0.250 0.275 mm. LAIL11TM1024A0A

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Engine - Connecting rods and pistons

Piston pin bushings - Assemble Prior operation: For installation of the piston rings, see Piston Ring - Assemble (10.105)

Installing the conrod shells 1. Install the shells (1) on the link conrods and covers. NOTICE: If the link conrod shells do not need to be replaced, they must be installed in exactly the same order and same positions in which they were found during disassembly. The link conrods are produced with a cutting technique that makes each link conrod and cover unique, with one single way of assembling. Do not modify the shells in any way.

LAIL11TM0943A0A

Next operation: For installation of the piston/conrod assembly in the cylinder sleeves, see Connecting rod and piston - Assemble the cylinder assembly (10.105).

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Index Engine - 10 Connecting rods and pistons - 105 Connecting rod and piston - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Connecting rod and piston - Assemble the cylinder assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Connecting rod and piston - Check cylinder assembly projection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Connecting rod and piston - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Connecting rod and piston - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Connecting rod and piston Connecting rod - Test twisting and warping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Connecting rod bearing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Connecting rod bearing - Backlash of the connecting rod journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Piston Pin - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Piston Ring - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Piston Ring - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Piston Ring - Measure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Piston pin bushings - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Engine - 10 Crankshaft and flywheel - 103

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine flywheel Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Crankshaft oil seal Front seal - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Crankshaft Journal - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Journal - Backlash of the main journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Speed ring - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Main bearings Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Crankshaft - Dimension Dimensions of main trunnions and the link conrod If there are any signs of scratches, galling or ovalisation of the trunnions or the link conrod they must be rectified. Before overhauling the trunnions, use a micrometer to measure the trunnions and define to what diameter you will reduce them. NOTE: Note down the values in the schematic below.

BRAG11TR0146LUE

BRAG11TR0147LUE

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Engine - Crankshaft and flywheel

BRAG11TR0148LUE

Objective characteristics of tolerance Roundness Cilindricity Parallelism Perpendicularity Flatness Concentricity or coaxiality Circular oscillation Total oscillation Conicity

Tolerances Shape

Guiding Position Oscillation

Class of importance associated to product characteristics Critical Important Secondary

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Graphic Symbol

Engine - Crankshaft and flywheel

Engine flywheel - Assemble Prior operation: To install the engine sump, see Engine oil pan - Assemble (10.102). 1. Check the condition of the rack teeth (2). If any tooth is broken or excessively worn, remove it from the flywheel (1) using a universal beater and install a new one, preheated to a temperature of 150 °C for 15 - 20 min; the internal diameter of the existing chamfer must face the side of the flywheel motor.

BRAG12TR0093LUE

BRAG12TR0094LUE

BRAG12TR0095LUE

BRAG12TR0096LUE

2. Install two suitable length pins (2) in the crankshaft holes (3) and using them as a guide, install the flywheel (1) in the crankshaft.

3. Assemble the flywheel (1) on the crankshaft. Adjust the bolts (2) by hand. 4. Install tool 380000988 to prevent the crankshaft from rotating.

5. Adjust the fixing bolts (1) on the engine flywheel (1) in two stages. • 1st Stage with torque meter 26 - 34 N·m. • 2nd Stage with angle of 55 - 65 °. NOTICE: Use an adequate angle meter to perform the final tightening. Before each assembly, always check whether the hole and bolt threads show wear or traces of dirt.

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Engine - Crankshaft and flywheel

Next operation: To install the oil filter head, see Engine oil filter - Assemble (10.304).

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Engine - Crankshaft and flywheel

Crankshaft oil seal Front seal - Disassemble 1. Extract the front cover seal. 2. Fit tool CNHT 0908 (4) to the front end of the crankshaft. Drill the seal with a 3.0 mm bit.

LAIL11TM0910A0A

LAIL11TM0911A0A

LAIL11TM0959A0A

3. Fasten the tool to the seal using the six bolts (3) supplied. 4. Extract the seal by turning the bolt (1) clockwise.

Assembly To complete the assembly, proceed as follows: 1. Place the front retainer onto the crankshaft flange. Install tool CNHT 0908 and tighten the central spindle anti-clockwise until the tool touches the cover.

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Engine - Crankshaft and flywheel

Crankshaft Journal - Assemble Prior operation: For installation of the oil spray nozzles, see Piston cooling Spray nozzle - Assemble (10.304) NOTICE: If the main bushing shells do not need to be replaced, they must be installed in exactly the same order and same positions in which they were found during disassembly. NOTE: The main shells (1) are supplied with replacement parts in internal diameter sub-measurements of 0.250 0.500 mm. NOTICE: Do not modify the shells in any way. 1. Carefully clean the shells (1) with the lubrication hole thoroughly and install them in their respective housings. 2. The penultimate shell in the main bushings (1) has semi-circular thrust washers.

LAIL11TM0933A0A

3. After installing the crankshaft bearings, measure the assembly clearance as in the procedure described in Crankshaft Journal - Backlash of the main journals (10.103). Next operation: For installation of the crankshaft, see Crankshaft - Assemble (10.103)

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Engine - Crankshaft and flywheel

Crankshaft - Assemble Prior operation: For assembly of the main bearing housings, see Crankshaft Journal - Assemble (10.103) 1. Check the crankshaft measurements, following Crankshaft - Dimension (10.103), before installing it. 2. Install the crankshaft (1) in its housing. 3. Check the clearance between the crankshaft main trunnions and their respective shells.

BRAG12TR0080LUE

Next operation: For installation of the main bushing caps, see Main bearings - Assemble (10.103)

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Engine - Crankshaft and flywheel

Crankshaft Journal - Backlash of the main journals 1. Check the clearance between the main crankshaft trunnions and their respective shells proceeding as described below. 2. Make sure all the parts are perfectly clean and with no traces of oil. 3. Position one calibrated wire segment (3) in the main trunnions (4), parallel to the axial shaft of the crankshaft. 4. Install the covers (1) with the shells (2) in their respective housings.

LAIL11TM1000A0A

LAIL11TM1001A0A

LAIL11TM1002A0A

5. Tighten the pre-lubricated bolts (1) in three successive stages. • 1st Stage with torque meter 47 - 53 N·m. • 2nd Stage with torque meter 75 - 85 N·m.

6. 3rd Stage with an angle meter (1) installed and positioned as in the figure, tighten the bolts (2) with an angle of 85 - 95 °.

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Engine - Crankshaft and flywheel

7. Remove the covers from their housings. 8. The clearance between the shell and the trunnion is obtained by comparing the width of the calibrated wire (2), at the point of greatest crushing with the graduation on the scale (1). 9. The numbers shown on the scale indicate the clearance in millimetres. 10. If the clearance found is different from specified replace the shells and repeat the check; after obtaining the specified clearance, lubricated the shells and install the bushings cover tightening the fixing bolts to the specified torque value.

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LAIL11TM1003A0A

Engine - Crankshaft and flywheel

Crankshaft Speed ring - Backlash Checking the crankshaft thrust ring clearance 1. Checking of the crankshaft thrust ring clearance is obtained by positioning a calibration gauge (2) with a magnetic base on the crankshaft (3). Normal assembled clearance is 0.068 - 0.410 mm. 2. If the clearance found is larger, replace the shells on the penultimate main bushing (1) and recheck the clearance between the shells and the main trunnions.

LAIL11TM1004A0A

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Engine - Crankshaft and flywheel

Main bearings - Assemble Prior operation: For installation of the crankshaft, see Crankshaft - Assemble (10.103) 1. Before installing the crankshaft bushing caps, measure the assembly clearance as in the procedure described in Crankshaft Journal - Backlash of the main journals (10.103). 2. Make sure all the parts are perfectly clean and with no traces of oil. 3. Install the covers (1) with the shells (2) in their respective housings.

LAIL11TM0935A0A

LAIL11FA0936A0A

LAIL11TM0937A0A

4. Before reusing the main bearing cover fixing bolts, take two measurements of the diameter as shown in the figure, measuring diameters D1 and D2. • If D1 – D2 < 0.1 mm, the bolt can be reused. • If D1 – D2 > 0.1 mm, the bolt must be replaced.

5. Tighten the pre-lubricated bolts (1) in three successive stages. • 1st Stage with torque meter 47 - 53 N·m. • 2nd Stage with torque meter 75 - 85 N·m.

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Engine - Crankshaft and flywheel

6. 3rd Stage with an angle meter (1) installed and positioned as in the figure, tighten the bolts (2) with an angle of 85 - 95 Â°.

LAIL11TM0938A0A

Next operation: For assembly of the piston/link conrod set, see Connecting rod and piston - Assemble (10.105)

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Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Crankshaft - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Crankshaft Journal - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Crankshaft Journal - Backlash of the main journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Crankshaft Speed ring - Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Crankshaft oil seal Front seal - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine flywheel - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main bearings - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Engine - 10 Balancer and damper - 110

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Balancer and damper - 110

SERVICE Balancer Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Balancer and damper

Balancer - Install Prior operation: To install the oil pump, see the procedures in Engine oil pump - Install (10.304). 1. Line up the gear markings (A) for synchronisation.

BRAG12TR0097LUE

BRAG12TR0038LUE

BRAG12TR0004LUE

2. Insert the pin in the orifice (B) in the additional mass group to momentarily block rotation.

3. Dynamic balancer additional bolts tightening sequence.

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Engine - Balancer and damper

4. Fit the additional masses (2) and adjust the bolts (3) to the specified torque. 5. Remove the blocking pin (1) from the additional masses.

BRAG12TR0070LUE

Next operation: To install the engine sump, see the procedures in Engine oil pan - Assemble (10.102).

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Index Engine - 10 Balancer and damper - 110 Balancer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Pump drives - 114

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Pump drives - 114

SERVICE Crankcase gears Crankcase gears - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Pump drives

Crankcase gears - Timing adjust 1. With a marker, mark the teeth on the driven gear (1) mounted on the crankshaft (2), on the side where the synchronism reference mark is stamped. NOTE: Screw in two pins to facilitate turning the crankshaft.

BRAG12TR0089LUE

BRAG12TR0058LUE

BRAG12TR0059LUE

BRAG12TR0091LUE

2. Position the crankshaft (3) and the camshaft (4) so the marks on gears (1) and (2) coincide.

3. Position the calibration gauge (1) on the distribution gear (2) and check that the clearance between gears (2) and (3) is between 0.076 - 0.280 mm.

4. Introduce the bolts (1) that fasten the gear (2) to the camshaft (3) and adjust it to the stated torque.

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Engine - Pump drives

5. Fit the gear (1) that transmits movement to the injection pump.

BRAG12TR0092LUE

BRAG12TR0081LUE

6. Introduce the power take-off gear (2) (if available) into its seat and adjust the bolts (1).

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Index Engine - 10 Pump drives - 114 Crankcase gears - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Lift pump and lines - 210

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Lift pump and lines - 210

SERVICE Fuel lift pump Diaphragm fuel pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Diaphragm fuel pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

(*) See content for specific models 73403953 04/04/2014

10.9 [10.210] / 2

Engine - Lift pump and lines

Fuel lift pump Diaphragm fuel pump - Remove 7630 8030

LA LA

1. Disconnect the supply pipes from the fuel tank to the transfer pump and the injector pump. 2. Remove the two fixing bolts (2) and remove the supply pump (1).

LAIL11TM0896A0A

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Engine - Lift pump and lines

Fuel lift pump Diaphragm fuel pump - Install 7630 8030

LA LA

Prior operation: To install the intake manifold, see Intake manifold - Assemble (10.254) . 1. Install the feed pump (1) together with a new seal and tighten the bolts (2) to the specified torque value.

LAIL11TM0987A0A

Next operation: For installation of the high pressure fuel line, see Injector fuel lines - Install (10.218).

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Index Engine - 10 Lift pump and lines - 210 Fuel lift pump Diaphragm fuel pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel lift pump Diaphragm fuel pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 73403953 04/04/2014

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Engine - 10 Fuel filters - 206

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Fuel filters - 206

SERVICE Fuel filters Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuel filters Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Fuel-water separator filter Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 73403953 04/04/2014

10.10 [10.206] / 2

Engine - Fuel filters

Fuel filters - Install Prior operation: To install the high pressure fuel line, see Injector fuel lines - Install (10.218). 1. Install the fuel filter head (4) . 2. Connect the fuel tubes (2) and (3), from feed pump to the filter head and from the head to the injection pump, respectively. 3. Install the fuel filter (1) . Connect the electrical cable on the bottom part of the filter. NOTICE: Before installing it, the diesel fuel filter must be filled with fuel to facilitate the fuel system de-aeration operation.

LAIL11TM1217B0A

LAIL11TM0991A0A

NOTICE: To connect the low pressure tubes to their fastenings, press the clips (1), as shown in (Fig. 2, [B]).

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Engine - Fuel filters

4. If used, install the steel screen prefilter (1) and connect the respective fuel lines.

LAIL11TM0992A0A

Next operation: To install the turbocharger, see Turbocharger - Install (10.250).

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Engine - Fuel filters

Fuel filters - Remove 7630 8030

LA LA

Removing the fuel filter 1. Place a receptacle under the main diesel filter. Disconnect the electrical cable (7) and loosen the drain plug (6), located under the filter. Drain out all the diesel content. NOTE: Always collect the fuel drained from the engine in an appropriate receptacle and discard the fuel in compliance with local legislation.

LAIL11TM0882A0A

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Engine - Fuel filters

Fuel-water separator filter - Remove 7630 8030

LA LA

Disassembling and assembling the steel screen fuel pre-filter (if installed) 1. Loosen the draining plug (2) and drain all the fuel contained in the sludge cup (1). NOTE: Always collect the fuel drained from the engine in an appropriate receptacle and discard the fuel in an adequate manner. 2. Disconnect the fuel inlet and outlet tubes from the filter and remove the complete filter.

LAIL11TM0883A0A

LAIL11TM0884A0A

3. Loosen the screw fixing the filter support to the engine and remove the assembly

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Engine - Fuel filters

Fuel-water separator filter - Disassemble 7630 8030

LA LA

1. Hold the sludge cup (1) with one hand and loosen the central bolt (2) two or three turns, enough to release the cup so that it turns freely.

LAIL11TM0885A0A

LAIL11TM0886A0A

LAIL11TM0887A0A

LAIL11TM0888A0A

2. By hand, turn the cup anti-clockwise and remove it from the central bolt.

3. Immobilise the central bolt head and remove the brass nut (1) from the bottom part of the filter, together with the rubber ring. 4. Remove the steel screen element (2).

(1) Central bolt with two washers (one metal and one rubber) (2) Head with rubber sealing ring (3) Dispersion plate (4) Steel screen element with rubber sealing washer (5) Rubber ring (6) Brass nut (7) Sludge cup

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Engine - Fuel filters

Fuel-water separator filter - Assemble 7630 8030

LA LA

1. During installation, check that the steel screen element is fitted correctly (1): install the element so that the face with the holes and the rubber sealing washer meets the head and the face with no holes faces inwards. 2. Install the rubber ring and brass nut. Tightening torque: 1.5 N路m (1.11 lb ft).

LAIL11TM0889A0A

LAIL11TM0890A0A

LAIL11TM0891A0A

3. Thread the sludge cup by hand and hold it in the correct position, that is, with the drain valve in the required position. 4. Carefully tighten the central bolt to the specified torque: 1.5 N路m (1.11 lb ft). The cup may make a clicking noise when seating on the head; this is normal and does not damage the filter.

5. After installation, check the gap in the filter between the brass nut and the central part of the cup: it should be 2 - 3 mm or more. If there is no gap, remove the cup and tighten the brass nut a little more: it can be tightened to 2.0 N路m (1.5 lb ft) to ensure there is a gap. 6. Verify the sludge cup tightening by hand. If there is any movement in the cup, retighten the cup and central bolt to 2.0 N路m (1.5 lb ft).

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Index Engine - 10 Fuel filters - 206 Fuel filters - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel filters - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fuel-water separator filter - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fuel-water separator filter - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuel-water separator filter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 73403953 04/04/2014

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Engine - 10 Fuel injection system - 218

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Rotary injection pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Fuel injection system Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Injector fuel lines Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Fuel injection system Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Rotary injection pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Fuel injectors Mechanical - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Mechanical - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Injector fuel lines Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Injector fuel lines - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 73403953 04/04/2014

10.11 [10.218] / 2

Engine - Fuel injection system

Rotary injection pump - General specification 7630 8030

LA LA

Infeed values of the pump 7630 0.95 - 1.05 mm

8030 0.95 - 1.05 mm

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Engine - Fuel injection system

Fuel injection system - Dynamic description 7630 8030

LA LA

The fuel system is composed of: • Fuel tank • Fuel lines to and from the tank • Fuel pre-filter • Fuel pump, installed in the engine and driven by the camshaft • Fuel pre-filter • Rotary injection pump • Injector supply lines (from the supply pump to the injectors) • Injectors

Operating description The fuel is sucked into the tank by means of a fuel pump mounted on the engine and driven by distribution shaft. The fuel is sent through the filter to the inlet fitting, which communicates with the transfer pump intake chamber. Then, the fuel reaches the valve, which regulates the pressure inside the supply pump. The distributor piston further increases this pressure and sends the fuel to the injectors through the sending connection. The fuel not used in the injectors is recovered and sent back to the tank.

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Engine - Fuel injection system

Injector fuel lines - Exploded view 7630 8030

LA LA

BRAG12TR0045LUE

1. 2. 3. 4.

Rear flange mounting bolt (attached to the intake manifold) Pump fuel return lines Rotary supply pump Pumper union nut

Injector

6. 7.

Flange mounting bolt â&#x20AC;&#x201C; injection pump side Front flange mounting bolt (attached to the intake manifold)

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Engine - Fuel injection system

Fuel injection system - Bleed 7630 8030

LA LA

Bleeding the fuel system 1. If any service was performed on the feed circuit components, the system must be bled. 2. Disconnect the fuel filter tube (3) and repeatedly pump the feed pump lever (2). 3. Continue pumping until fuel comes out without the presence of air. 4. Connect the tube (3) to the fuel filter.

LAIL11TM1070A0A

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Engine - Fuel injection system

Rotary injection pump - Remove 7630 8030

LA LA

1. Remove the starter motor (2) by loosening the fixing bolts (1).

LAIL11TM1039A0A

LAIL11TM1040A0A

LAIL11TM1041A0A

LAIL11TM1042A0A

2. Install tool (1) No. 380000988 and turn the engine using the tool until the milled channel in the flywheel is visible. NOTE: The machined channel on the flywheel is a reference for the first cylinder Top Dead Centre (TDC).

3. Insert the tool pin (1) in the block orifice and carefully turn the engine in the normal direction until the pin fits into the flywheel channel. In this condition, the first cylinder piston is at TDC. NOTE: After locating the TDC, it is important to turn the engine in the normal rotating direction to eliminate gear clearance. NOTICE: Do not forget to remove the pin afterwards to prevent damage.

4. Loosen the input and exhaust tubes from the fuel feed mechanical pump (1) and remove the pump by loosening the fixing bolts (2).

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Engine - Fuel injection system

5. Check on the feeder pump housing that the reference marks (2) on the camshaft (1) are visible: this guarantees that the piston in cylinder no. 1 is at TDC in the compression phase. If the markings are not evident, remove the tool pin and turn the engine 360ยบ (one turn) until the lock pin fits in again. NOTE: These two indications (pin fitted in flywheel and visible marks on camshaft) guarantee that the first cylinder in the engine is at TDC, in the compression phase. One other way would be to balance the 6th cylinder rocker arms, but this is less precise than the above way. LAIL11TM1043A0A

LAIL11TM1044A0A

LAIL11TM1045A0A

LAIL11TM1046A0A

6. Remove the injection pump gear cover by removing its two fixing bolts. 7. Remove the injection pump gear fixing nut (1).

8. Install extractor No. 291182 and loosen the injection pump gear shaft. Make sure the gear is free and remove the puller.

9. Disconnect all the injection pump and feed pump fuel intake and exhaust tubes, injection nozzle return to the pump and the LDA tube. Disconnect the electric cables. 10. Remove the bolt (1) and the two fixing nuts from the injection pump to the engine block. Remove the injection pump.

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Engine - Fuel injection system

Rotary injection pump - Timing adjust 1. Install two nuts on the injection pump shaft and tighten them against each other. 2. Use the nuts to turn the injection pump shaft, align the keyway slit (1) on the shaft with the marking (2) on the pump carcass.

LAIL11TM1047A0A

LAIL11TM1048A0A

LAIL11TM1049A0A

3. Fasten the injection pump to a vice with the nuts installed on the pump shaft. 4. Remove the limiting screw on the injection pump piston and in its place install a comparison gauge with tool (3) No. 380001601, with a minimum pre-load on the gauge of 2.5 mm. 5. Partly loosen the pump shaft side locking bolt (1) and remove the spacer (2). 6. Set the calibrator gauge to zero.

7. Turn the pump ANTI-CLOCKWISE until you get the advance reading specified in Rotary injection pump General specification (10.218). Hold the pump position and tighten the side bolt (1) to block the pump shaft rotation. 8. Remove the tool and calibrator gauge and reinstall the injection pump piston limiting bolt.

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Engine - Fuel injection system

Rotary injection pump - Install 7630 8030

LA LA

1. Ensure that the first engine cylinder is at TDC on the compression stroke, as described in Engine - General specification (10.001). 2. Install the injection pump (after synchronising with the previous procedure) on the engine block turning it slightly so that if fits into the studs and the gear.

LAIL11TM1050A0A

LAIL11TM1051A0A

LAIL11TM1052A0A

LAIL11TM1053A0A

3. Tighten the injection pump bolt and the two fixing nuts on the block to the specified torque.

4. Install the gear fixing nut and tighten is with a torque of 40 NÂˇm (29.5 lb ft).

5. Partly loosen the pump shaft side locking bolt (1) and insert the spacer (2). Tighten the bolt (1) to lock the spacer and thereby allow the injection pump shaft to turn freely.

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Engine - Fuel injection system

6. Apply final torque of 90 NÂˇm (66 lb ft) to the gear fixing nut on the injection pump. 7. Install the gear cover and tighten the two fixing bolts.

LAIL11TM1054A0A

LAIL11TM1055A0A

LAIL11TM1056A0A

8. Install the fuel feed pump (1) and tighten the fixing bolts (2) to the specified torque value.

9. Remove special tool 380000988 and the TDC localisation pin. 10. Install the starter motor (2) in its housing and tighten the fastening bolts (1). 11. Connect all the injection pump and feed pump fuel intake and exhaust tubes, injection nozzle return to pump and the LDA tube. Connect all the electric cables.

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Engine - Fuel injection system

Rotary injection pump - Check 7630 8030

LA LA

Checking injection pump synchronism This procedure is used to check the injection pump synchronism without removing it, installed on the tractor. This procedure is important to diagnose any eventual problems with engine overheating, lower than specified power and excess fuel consumption. NOTICE: The rotating injection pump injection point checking procedure can be carried out with the engine installed on the tractor or the trestle. 1. Remove the starter motor (2) by loosening the fixing bolts (1).

LAIL11TM1057A0A

LAIL11TM1058A0A

LAIL11TM1059A0A

2. Install tool No. 380000988 and turn the engine using the tool until the milled channel in the flywheel is visible. NOTE: The machined channel on the flywheel is a reference for the first cylinder Top Dead Centre (TDC).

3. Remove the injection pump piston limiting bolt.

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Engine - Fuel injection system

4. Introduce a calibration gauge (1) with tool (2) No. 380001601 in the injection pump, with a minimum pre-load on the gauge of 2.5 mm.

LAIL11TM1060A0A

LAIL11TM1061A0A

LAIL11TM1062A0A

LAIL11TM1063A0A

5. Turn the engine slowly anti-clockwise until the pump piston reaches its BDC. While the engine is turned, the value recorded by the calibration gauge recedes until the arrow stops. In this position, the injection pump is at BDC. NOTE: Always take as reference the operator position. The normal engine turning direction is clockwise for an observer seated at the operator seat.

6. Set the calibrator gauge to zero. NOTE: Check the position of the “smaller” calibration gauge arrow. Some models may have advances of more than 1 mm, o.e. one full turn of the “larger” calibration gauge arrow.

7. Insert the tool pin in the block orifice and carefully turn the engine clockwise until the pin fits into the flywheel channel. NOTE: In this condition, the first cylinder piston is at TDC. To make sure the first cylinder piston is in the compression travel perform the next step. NOTICE: Do not forget to remove the pin afterwards to prevent damage.

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Engine - Fuel injection system

8. Loosen the input and exhaust tubes from the fuel feed mechanical pump (1) and remove the pump by loosening the fixing bolts (2).

LAIL11TM1064A0A

LAIL11TM1065A0A

9. Check on the feeder pump housing that the reference marks (2) on the camshaft (1) are visible: this guarantees that the piston in cylinder no. 1 is at TDC in the compression phase. If the markings are not evident, remove the tool pin and turn the engine 360ยบ (one turn) until the lock pin fits in again. NOTE: These two indicators (pin fitted in the flywheel and markings on the camshaft axle in view) ensure the first engine cylinder is at TDC in the compression phase. One other way would be to balance the 6th cylinder rocker arms, but this is less precise than the previous way. 10. The point of the calibration gauge should show the specified value of 0.95 - 1.05 mm, corresponding to the pistons advance in the injection pump. If the value is not correct, proceed with the next steps.

LAIL11TM1066A0A

LAIL11TM1067A0A

11. Loosen the two nuts and the bolt (1) that fasten the pump to the engine block.

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Engine - Fuel injection system

12. Turn the injection pump to the engine side (anti-clockwise) to increase and outward (clockwise) to reduce the injection pump piston advance. NOTE: The pump must be fastened to the block with the bolt positioned close to the carcass oblong centre. This allows the pump to be moved both clockwise and anti-clockwise.

LAIL11TM1068A0A

LAIL11TM1069A0A

13. Tighten the bolt (1) and the two fixing nuts from the injection pump to the engine block and apply the specified torque. NOTE: Run the procedure again to check adjustment.

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Engine - Fuel injection system

Fuel injectors Mechanical - Remove 7630 8030

LA LA

1. To remove the injector nozzles, use the adapter CNHT 0910and the sliding hammer CNHT 0013 (2)

LAIL11TM0895A0A

LAIL11TM0980A0A

NOTE: The injector nozzles have a safety sphere that locks the element in its housing. Correctly align the injector nozzle to remove it.

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Engine - Fuel injection system

Fuel injectors Mechanical - Assemble 7630 8030

LA LA

Prior operation: For installation of the rocker arm assembly, see Rocker arm - Assemble (10.106) 1. Install the injection nozzles after replacing the seals (1). NOTICE: During installation of the injection nozzles, check if the injection nozzle sphere is seated on its seat on the cylinder head.

LAIL11TM0980A0A

Next operation: For installation of the valve seals, see Valves Seal - Assemble (10.101).

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Engine - Fuel injection system

Injector fuel lines - Remove 7630 8030

LA LA

See the exploded view of the system in Injector fuel lines - Exploded view (10.218). 1. To remove the fuel return and feed tubes (2) between the pump and the injectors: loosen the nuts holding the tubes to the pump elements; loosen the clamp holding the fuel return tube to the injection pump; loosen the nuts on the injectors and loosen the fixing bolts on the fuel return tube; loosen the bolts (1) holding the supports of the tubes mentioned above. .

LAIL11TM0894A0A

2. Remove the engine tubing. Plug the ends of the tubes to avoid contamination.

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Engine - Fuel injection system

Injector fuel lines - Install 7630 8030

LA LA

Prior operation: For installation of the feed pump, see Fuel lift pump Diaphragm fuel pump - Install (10.210). See the exploded view of the fuel line in Injector fuel lines - Exploded view (10.218). 1. Install fuel return and feed tubes (2) between the pump and the injection nozzles. 2. Tighten the fixing bolts from the tubes to the pumping elements; tighten the clamp from the fuel return tube to the injection pump; tighten the fixing bolts from the fuel return tube to the injection pump; tighten the injector nuts and tighten the fixing bolts (1) on the tube supports mentioned above.

LAIL11TM0989A0A

LAIL11TM2124A0A

3. Fasten the LDA tube (1) to the cylinder head and the injection pump.

Next operation: To install the fuel filter, see Fuel filters - Install (10.206).

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Index Engine - 10 Fuel injection system - 218 Fuel injection system - Bleed (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fuel injection system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Fuel injectors Mechanical - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Fuel injectors Mechanical - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Injector fuel lines - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Injector fuel lines - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Injector fuel lines - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rotary injection pump - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rotary injection pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rotary injection pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rotary injection pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rotary injection pump - Timing adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(*) See content for specific models 73403953 04/04/2014

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Engine - 10 Turbocharger and lines - 250

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Turbocharger and lines - 250

SERVICE Turbocharger Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Turbocharger and lines

Turbocharger - Remove 1. Loosen the nut (1) and disconnect the turbocharger lubrication tube. Proceed in a similar way on the other end of the tube and disconnect it from the top of the oil heater. 2. Loosen the fastening nuts (2) from the turbocharger to the exhaust manifold. 3. Loosen the turbocharger (5), lift it and remove the gasket. 4. Loosen the fastening nuts (3) and remove the exhaust manifold (4). LAIL11TM0881A0A

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Engine - Turbocharger and lines

Turbocharger - Install Prior operation: To install the fuel filter, see Fuel filters - Install (10.206). To install the turbocharger: 1. Support the turbocharger and position it over the exhaust manifold after having inserted a new gasket. 2. Tighten the fixing bolts from the turbocharger to the exhaust manifold to the specified torque value. 3. Tighten the turbocharger lubrication tube nut (1). Proceed in a similar way on the other end of the tube and connect it to the top of the oil cooler.

LAIL11TM0993A0A

LAIL11TM1739A0A

Tightening sequence for turbocharger bolts and nuts: 4. Pre-tighten (4) - (3) - (1) - (2) 5. Tighten (1) - (4) - (2) - (3)

To find the recommended torque values, see Engine Torque (10.001) Next operation: Final engine assembly operations, check Engine - Assemble (10.001) from stage 32.

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Index Engine - 10 Turbocharger and lines - 250 Turbocharger - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Turbocharger - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - 10 Intake and exhaust manifolds and muffler - 254

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Intake and exhaust manifolds and muffler - 254

TECHNICAL DATA Intake and exhaust manifolds and muffler Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Intake and exhaust manifolds and muffler Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Intake manifold Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Exhaust manifold Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 73403953 04/04/2014

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Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Torque Air intake union installation (M8 x 1.25) Intake manifold installation (M8 x 1.25) Exhaust manifold installation (M10 x 1.5 x 65) (see Exhaust manifold - Assemble (10.254) )

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20 - 28 N·m 20 - 28 N·m 37 - 49 N·m

Engine - Intake and exhaust manifolds and muffler

Intake and exhaust manifolds and muffler - Dynamic description 7630 8030

LA LA

The air intake system is composed of an air filter, a turbocharger, and an engine radiator. The turbocharger is composed of the following main parts: a turbine, a boost pressure regulating valve, a central body, and a compressor. During engine operation, exhaust gases pass through the turbine body, rotating its rotor. The compressor rotor, being connected through the shaft to the turbine rotor, rotates with it, compressing the air through the air filter, which is cooled by the radiator and sent through the intake manifold to the pistons. The turbocharger has a pressure regulating valve located on the exhaust manifold before the turbine and connected by lines to the intake manifold. Its function is to limit the output of exhaust gases by sending a part directly to the exhaust pipe when the boost pressure after the turbocharger reaches the prescribed value.

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Engine - Intake and exhaust manifolds and muffler

Intake manifold - Assemble 7630 8030

LA LA

Prior operation: For installation of the alternator belt, see Belt - Assemble (10.414). 1. Position the joint (3) and install the inlet manifold plate (1). Tighten the bolts (2) to the specified torque value. 2. If the tube (7) has been removed from the intake manifold plate (1), reinstall it and replace the seal (6). 3. Tighten the bolts (8) to the specified torque value. NOTICE: On versions fitted with a cold start heater, also install parts (4) and (5).

BRAG12TR0028LUE

LAIL11TM0986A0A

4. Install the fastening support (1) of the injection nozzle pressure tubes; use the same intake manifold plate fastening bolts (2) as shown in Fig. 2.

Next operation: To install the feed pump, see Fuel lift pump Diaphragm fuel pump - Install (10.210).

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Engine - Intake and exhaust manifolds and muffler

Exhaust manifold - Assemble 7630 8030

LA LA

Prior operation: To install the valve seals, see Valves Seal - Assemble (10.101). 1. Tightening sequence for exhaust manifold bolts. Check Engine - Torque (10.001) to find the recommended values.

BRAG12TR0029LUE

BRAG12TR0031LUE

Installing the exhaust manifold 2. Install the exhaust manifold (1) together with new gaskets (2).

Next operation: For installation of the thermostat, see Coolant thermostat - Assemble (10.400).

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Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust manifold - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Intake and exhaust manifolds and muffler - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Intake and exhaust manifolds and muffler - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Intake manifold - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 73403953 04/04/2014

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Engine - 10 Engine cooling system - 400

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Engine cooling system - 400

FUNCTIONAL DATA Engine cooling system Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Water pump Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Coolant thermostat Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 73403953 04/04/2014

10.14 [10.400] / 2

Engine - Engine cooling system

Engine cooling system - Static description 7630 8030

LA LA

The closed circuit, forced circulation cooling system comprises the following components: • Expansion tank: Its location, shape and size depends on the engine version. • Radiator, whose function is to dissipate the heat that the coolant absorbs from the engine. This component is also dependent on the version and positioning of the engine. • Lubricating oil cooler. • Centrifuge water pump housed in the front part of the cylinder block. • Thermostat that controls coolant circulation. • The circuit can also be extended to the air compressor if it is included in the version. Cooling system diagram A: Flow from engine to radiator B: Flow from radiator to engine

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Engine - Engine cooling system

BRAG11TR0165LUE

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Engine - Engine cooling system

Water pump - Install 7630 8030

LA LA

Prior operation: For assembly of the engine front cover, see Engine block cover Front - Assemble (10.102). 1. Install a new seal (2) in the water pump (1).

LAIL11TM0953A0A

LAIL11TM0954A0A

2. Install the water pump (1); tighten the bolts (2) to the specified torque.

Next operation: To install the oil pump, see Engine oil pump - Install (10.304)

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Engine - Engine cooling system

Coolant thermostat - Remove 7630 8030

LA LA

1. Remove the three fastening bolts (1) and disassemble the thermostat group (2), the gasket (3) and the thermostat (4).

BRAG12TR0043LUE

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Engine - Engine cooling system

Coolant thermostat - Assemble 7630 8030

LA LA

Prior operation: To install the exhaust manifold, see Exhaust manifold - Assemble (10.254). 1. Install the bolts (1), the thermostat body (2) with the thermostat (4) and the gasket (3) NOTE: The gasket (3) must be new.

BRAG12TR0043LUE

Next operation: For installation of the fan pulley, see Idler pulley - Assemble (10.414).

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Index Engine - 10 Engine cooling system - 400 Coolant thermostat - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Coolant thermostat - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Engine cooling system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Water pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Engine - 10 Fan and drive - 414

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Fan and drive - 414

SERVICE Belt Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Idler pulley Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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10.15 [10.414] / 2

Engine - Fan and drive

Belt - Assemble 7630 8030

LA LA

Prior operation: For installation of the the alternator idler, see Idler pulley - Assemble (10.414). 1. Install the support (1) for the fan pulley with the bolts (2). Adjust the bolts to the prescribed torque.

BRAG12TR0099LUE

BRAG12TR0100LUE

BRAG12TR0101LUE

2. Assemble the fan pulley (2) on the support (1) with the bolts (3). Tighten the bolts to the prescribed torque.

3. Mount the belt tensioner (1) with the bolt (2). Tighten the bolt to the prescribed torque. See Engine - Torque (10.001) .

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Engine - Fan and drive

4. Mount the Poli-V belt (3) on the crankshaft pulley, on the water pump (4), on the alternator (1), and on the fan pulley (2). NOTE: Adjust the belt tension by operating the tensioner (5). If reassembling the same belt, check thoroughly for cuts or obvious signs of loosening.

BRAG12TR0102LUE

Next operation: Installing the inlet manifold, check Intake manifold - Assemble (10.254).

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Engine - Fan and drive

Idler pulley - Assemble 7630 8030

LA LA

Prior operation: For installation of the thermostat, see Coolant thermostat - Assemble (10.400). 1. Install the base (4) of the pulley and tighten the bolts to the specified torque value. 2. Install the pulley (3) and fasten it with the bolts (2). 3. Install intermediate pulley (1). 4. Install the automatic tensioner (5) and fasten it with the bolt (6). Tighten the bolt to the specified torque value.

LAIL11TM0983B0A

Next operation: Check Belt - Assemble (10.414) when fitting the alternator belt.

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Index Engine - 10 Fan and drive - 414 Belt - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Idler pulley - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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10.15 [10.414] / 6

Engine - 10 Engine lubrication system - 304

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Engine lubrication system - 304

FUNCTIONAL DATA Engine lubrication system Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Engine oil filter Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine oil pump Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gear driven - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Piston cooling Spray nozzle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Engine - Engine lubrication system

Engine lubrication system - Static description 7630 8030

LA LA

The forced circulation lubrication system is complemented by the oil pump housed in the front part of the cylinder block. The lubricant oil is sent from the sump to the crankshaft, camshaft and control valves. The lubrication system also includes the oil cooler and the turbocharger. All these components may change according to use and will be covered further on under specific titles.

BRAG12TR0046LUE

1. 2. 3.

Piping for sending lubrication to the turbocharger Oil filter Heat exchanger body

4. 5.

Heat Exchanger Oil pump

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Engine - Engine lubrication system

Engine oil filter - Assemble 7630 8030

LA LA

Prior operation: For engine flywheel assembly, see the procedures described in Engine flywheel - Assemble (10.103) . 1. Install the oil cooler following in the procedures described in Engine oil cooler - Assemble (10.408). 2. Position a new seal (1) on the cylinder block seat to the coolant inlet connector.

LAIL11TM0968A0A

LAIL11TM0969A0A

3. Install the coolant inlet connector (1) and tighten the bolts (2) to the specified torque value. NOTICE: Before each assembly, always check whether the hole and bolt threads show wear or traces of dirt.

Next operation: To install the alternator, see the procedures in Alternator - Install (55.301).

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Engine - Engine lubrication system

Engine oil pump - Install 7630 8030

LA LA

Prior operation: To install the water pump, see the procedures in Water pump - Install (10.400). 1. Remove the seal (2) from the oil pump/front cover (1). Carefully clean the seal housing.

LAIL11TM0955A0A

LAIL11TM0957A0A

LAIL11TM0958A0A

2. Carefully clean the contact surface on the cylinder block and position the gasket (1) on the block.

3. Install the front cover/oil pump on the cylinder block and tighten the bolts to the specified torque value.

4. Fit the crankshaft front seal following the procedures described in Crankshaft oil seal Front seal - Disassemble (10.103)

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Engine - Engine lubrication system

5. Install the pulley (1) and the spacer ring (3) on the crankshaft. 6. Tighten the fixing bolts (2) to the specified torque. • 1st Stage with torque meter 45 - 55 N·m . • 2nd Stage angle: 85 - 95 ° 7. Install a new sealing ring on the speed sensor (4) and install the sensor in the front cover, tightening the fixing bolt.

LAIL11TM0960A0A

Install the dynamic balancer following the procedures described in Balancer - Install (10.110). Next operation: Installing the engine sump, check Engine oil pan - Assemble (10.102).

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Engine - Engine lubrication system

Engine oil pump Gear driven - Replace 7630 8030

LA LA

1. Check that the teeth on the sprocket (1) on the crankshaft (2) are not faulty or worn. If they are, construct two identical and diametrically opposed channels on the sprocket (1) and remove using a suitable extractor. 2. To install the new gear, it has to be heated in an oven for 60 s at most, at a constant temperature of 160 Â°C. After this, install on the crankshaft.

BRAG12TR0035LUE

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Engine - Engine lubrication system

Piston cooling Spray nozzle - Assemble 7630 8030

LA LA

Prior operation: Installation of camshaft tappets, check the procedures described in Camshaft - Assemble (10.106).

Installing oil spray nozzles 1. Position the spray nozzles (2) and tighten the fixing bolts (1) to the specified torque ( 12 - 18 NÂˇm).

LAIL11TM0932A0A

Next operation: Assemble the main crankshaft bearings Crankshaft Journal - Assemble (10.103)

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Index Engine - 10 Engine lubrication system - 304 Engine lubrication system - Static description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine oil filter - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine oil pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine oil pump Gear driven - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Piston cooling Spray nozzle - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

(*) See content for specific models 73403953 04/04/2014

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Engine - 10 Oil cooler and lines - 408

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Engine - 10 Oil cooler and lines - 408

SERVICE Engine oil cooler Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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10.17 [10.408] / 2

Engine - Oil cooler and lines

Engine oil cooler - Assemble 7630 8030

LA LA

Tightening sequence 1. Tightening sequence for heat exchanger bolts.

LAIL11TM1907G0A

LAIL11TM0967A0A

Assembly 1. Install the following in the cylinder block: a new gasket (1), the oil cooler (2), a new gasket (3) and the oil filter head (4). 2. Tighten the bolts (5) to the specified torque value. NOTICE: Before each assembly, always check whether the hole and bolt threads show wear or traces of dirt.

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Index Engine - 10 Oil cooler and lines - 408 Engine oil cooler - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

NEW HOLLAND policy is one of continuous improvement and the right to change prices, specification or equipment at any time without notices is reserved. All data given in this publication is subject to production variations. Dimensions and weight are approximate only and the illustrations do not necessarily show products in standard condition. For exact information about any particular product, please consult your NEW HOLLAND Dealer.

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SERVICE MANUAL Clutch

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Clutch - 18

[18.104] Clutch hydraulic release control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.2

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CONSUMABLES INDEX Consumable

Reference

NEW HOLLAND AMBRA GR Clutch - General specification 75 MD

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PAGE 18.2 / 4

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Clutch - 18 Clutch hydraulic release control - 104

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Clutch - 18 Clutch hydraulic release control - 104

SERVICE Clutch hydraulic release control Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Clutch hydraulic release control Clutch hydraulic release control - Travel adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Disassemble Prior operation: Clutch - Disassemble (18.110) 1. Lever up the pedal return spring. (1). 2. Remove the snap ring from the clutch pedal shaft . 3. Remove the clutch pedal shaft. 4. Remove the clutch pedal (2).

36087826A

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Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Inspect Prior operation: Clutch hydraulic release control - Disassemble (18.104) 1. Inspect the clutch pedal. Check for cracks and make sure there is not excessive free play between the bushings and the pedal shaft. Remove and replace damaged parts. 2. Inspect the release clutch cross shaft and bushings inside transmission box. Shaft should rotate smoothly on its bushings without free play between bushings and shaft. If bushings are damaged or worn out, replace the bushings.

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Clutch - Clutch hydraulic release control

Clutch hydraulic release control - Travel adjust 7630 8030

LA LA

Clutch adjustment The only adjustment the clutch requires is, when required, adjusting the clutch pedal free travel. This is the amount of pedal movement from the fully released position to the point where the first resistance is found.

Adjustment procedure The clutch pedal free travel must be of 28 - 41 mm (1.1 1.6 in) at the clutch pedal. If adjustment is required, loosen the locknut, (1) remove the cotter pin (4) and the joint pin (3). Rotate the joint pin (3) to lengthen or shorten the operating connecting rod as necessary. Install the joint pin (3) with a new cotter pin (4) and tighten the locknut (1).

20087234

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Index Clutch - 18 Clutch hydraulic release control - 104 Clutch hydraulic release control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Clutch hydraulic release control - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch hydraulic release control - Travel adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Clutch - 18 Clutch and components - 110

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Clutch Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Clutch Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - PTO drive disc bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install - PTO drive disc bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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CONSUMABLES INDEX Consumable

Reference

NEW HOLLAND AMBRA GR Clutch - General specification 75 MD

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PAGE 18.2 / 4

Clutch - Clutch and components

Clutch - General specification Component Disc type Material Pressure plate type Thrust bearing type Clutch pedal free play setting Transmission input shaft lubricant

Specification dry disc, 330 mm Organic, asbestos free Belleville spring (self-adjustment, maintenance free) Mechanical activation. 28 - 41 mm (1.102 - 1.614 in) NEW HOLLAND AMBRA GR 75 MD molybdenum lithium grease, amber colour

Clutch - Torque 7630 8030

LA LA

Component Screws from clutch cover to flywheel Locknut on clutch pedal Drive disc screws of PTO Bearing fork setscrew on crosswise shaft

35 N路m (26 lb ft) 34 N路m (25 lb ft) 129 N路m (95 lb ft) 47 N路m (35 lb ft)

Specification

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Clutch - Clutch and components

Clutch - Exploded view Disengage bearing set / slave cylinder

LAIL11TS0311F0A

1. 2. 3. 4. 5.

Casing Protective cover set Bearing assembly. Locking ring Sealing ring

6. 7. 8. 9. 10.

O-Ring Guide segment Piston Guide segment Sealing ring

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11. 12. 13. 14. 15.

Locking ring Guide sleeve Sealing ring Auxiliary sealing ring collar O-Ring

Clutch - Clutch and components

Clutch - Overview • The non-synchronised 8x2 transmission clutch system is mechanically driven with a single dry 330-mm disc. • The pressure plate a self-adjustable spring type and does not require any maintenance. • There is a pre-lubricated thrust bearing on the rear end of crankshaft, inside the flywheel. The bearing is placed on drive disc of PTO. • With the clutch engaged, the spring loaded pressure plate forces the clutch disc into contact with the engine flywheel. • Friction contact between disc material and the surfaces of the flywheel and pressure plate transmits drive from the flywheel shaft to the transmission input shaft via the disc. • When placing your foot on the clutch pedal, the thrust bearing moves forward and pushes the pressure plate, separating the clutch disc and disconnecting it from the flywheel. As a result, the friction disc disconnects from the transmission, allowing gear changing to occur. • When the clutch pedal is let out, a spring places the pedal back into its free position and the thrust bearing separates from the pressure plate pins. • The pressure plate springs exert pressure forward against the disc until it touches the clutch, thus restoring drive between the engine and the gear box.

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Clutch - Clutch and components

Clutch - Check Inspecting and repairing Friction disk Inspect the clutch disk to ensure that the liners are not loose, fractured, worn or contaminated with oil. Check the rivets that fasten the friction material to the disc. If there is evidence of overheating due to the clutch slipping too much, discard the disk and replace with a new one. NOTICE: Investigate the source of any oil or lubricating grease on the faces and overhaul before installing a new disk.

Pressure plate Examine the pressure plate set, make sure the diaphragm fingers are all at the same height, there is no discoloring due to excessive heat and that the set operates easily. Check the pressure plate face for fractures, grooves or deformation. Discard the plate if any faults are found. NOTE: The diaphragm type clutch has no reusable components. It must be replace by a new set if faults are found during the inspection.

Disengage bearing set / slave cylinder Inspect the disengage bearing for the following signs: an oil leak, a weak, broken or worn return spring, or damages to the disengage bearing. Repair kits are available in the case of the seals or if the bearing set needs servicing.

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Clutch - Clutch and components

Clutch - Assemble Review the hydraulic disengage bearing set/slave cylinder. With reference to Clutch - Exploded view (18.110). 1. Disassemble the bearing retaining brake, item (4), and remove the set from the bearing. 2. Lift with a lever very carefully and open the catches of the bearing housing and remove the set from the piston. 3. Remove the lock from the backs of the housing and remove the guide sleeve. 4. When disassembling the slave cylinder it is best to replace the seals for new ones as a precautionary measure against future problems. Inspect the other components for wear or damage and replace as necessary.

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Clutch - Clutch and components

Clutch - Disassemble Assemble Assemble once again in reverse order as used to disassemble. Smear all the seals with clean brake fluid of the correct specification as you install and assemble them.

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Clutch - Clutch and components

Clutch - Adjust The only adjustment the clutch requires is a periodic adjusting of the free travel of the pedal. This is the movement in which the pedal goes from being totally loose to the point when it encounters resistance. This is the only adjustment required for the mechanical clutch. 1. Measure the free travel of the clutch pedal. Specification is 28 - 41 mm (1.102 - 1.614 in).

20087234

2. If free travel is not within specifications: A. Loosen the locknut (1) on the clutch rod assembly (2). B. Remove the split (cotter) pin (4) and the clevis pin (3) securing the clutch rod assembly to the clutch release shaft assembly. C. Make the necessary adjustments. D. Install a new split pin and the clevis pin. Make sure the clevis pin is installed with the cotter pin side AWAY from the fuel tank. E. Tighten the locknut to a torque of 34 NÂˇm (25 lb ft). Next operation: Clutch - Remove (18.110)

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Clutch - Clutch and components

Clutch - Remove 1. Separate the engine and the transmission. 2. Remove the bolts (1) that affix the pressure plate and cover (2) to the flywheel. NOTE: Loosen the bolts equally and diagonally to avoid distortion of the cover. 3. Remove the pressure plate and the clutch disc.

36087824

Next operation: Clutch - Disassemble (18.110)

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Clutch - Clutch and components

Clutch - Disassemble Prior operation: Clutch - Remove (18.110) 1. Remove the clutch release fork setscrew (3). 2. Remove the clutch release shaft (4) from the box. 3. Remove the fork (2) from the transmission. 4. Push out the thrust bearing (1) and hub assembly from the clutch hub support.

36087825

Next operation: Clutch - Inspect (18.110)

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Clutch - Clutch and components

Clutch - Inspect Prior operation: Clutch - Disassemble (18.110) 1. Inspect the friction disc. Make sure the linings are not loose, cracked, worn out or dirtied by oil. Check the rivets. If there are signs of overheating due to clutch slippage, replace the disc with a new one. NOTE: Investigate reason for any oil or grease on surfaces. Repair before mounting new disc. 2. Inspect pressure plate. Check that all pins are the same height, that there is no discoloration due to overheating, and that the entire assembly works properly. Check for cracks, scratches or distortion on the surface of the pressure plate. Dispose of pressure plate if any of the above failures are found. NOTE: The diaphragm clutch has no replacement parts. Replace the whole assembly if any problem is found during inspection. 3. Make sure the thrust bearing and hub move freely inside the hub support. Ensure the bearing rotates smoothly and that external side is not damaged or worn out. Look for cracks or distortion on clutch release fork. For example, make sure that all the pins are aligned and not worn out. Remove and replace any broken or defective parts. 4. If needed, check the thrust bearing. Use a puller (1) with a suitable attachment (3) and a stack plate (4) to separate the thrust bearing (2) from the hub.

36087827

Next operation: Clutch - Assemble (18.110)

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Clutch - Clutch and components

Clutch - Assemble Prior operation: Clutch - Inspect (18.110) 1. Lubricate hub housing with high melting point grease and install the thrust bearing and hub. 2. Reattach the fork and the clutch release shaft. 3. Tighten the fork setscrew to a torque of 47 NÂˇm (35 lb ft). Next operation: Clutch - Install (18.110)

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Clutch - Clutch and components

Clutch - Install Prior operation: Clutch - Assemble (18.110) NOTICE: When installing a new pressure plate, the friction surface must be thoroughly cleaned with alcohol to remove the protective enamel. 1. Lightly lubricate hub splines of the transmission input shaft with non-fibrous lithium based grease. 2. Use the pilot tool to place the clutch disc with the run surface and clutch plates towards flywheel. 3. Place the pressure plate over the flywheel and tighten the bolts to 35 NÂˇm (26 lb ft). 4. Remove the pilot tool from clutch disc. 5. Reconnect the engine and the transmission. Next operation: Clutch - Adjust (18.110)

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Clutch - Clutch and components

Clutch - Remove - PTO drive disc bearing Prior operation: Clutch - Remove (18.110) Use a slide hammer (2) and suitable puller attachment (1) to remove the ball bearing (3) from the flywheel adapter.

36087828

Next operation: Clutch - Install - PTO drive disc bearing (18.110)

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Clutch - Clutch and components

Clutch - Install - PTO drive disc bearing Prior operation: Clutch - Remove - PTO drive disc bearing (18.110) Place a stake plate (1) so that the flat side faces outwards and use a suitable driver to install the ball bearing (3) in the flywheel adapter (2) for the PTO drive disc.

36087829

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Clutch - Clutch and components

Clutch - Remove Prior operation: To separate the engine and transmission: . Engine - Remove the engine from the transmission (10.001) Remove the bolts that hold the clutch pressure plate and the cover assembly to the flywheel and disassemble the pressure plate set together with the clutch disk. NOTE: The bolts must be loosened evenly and diagonally through the clutch to prevent the cover assembly from being twisted.

LAIL11TS0671A0A

LAIL11TS0672A0A

36087825

1. At the front of the transmission, disassemble both tubes (2) from the hydraulic disengage bearing (1). Remove the three bolts that attach the disengage bearing set to the transmission front plate and remove the disengage bearing set.

Remove the clutch disengage fork retaining bolt, (3), and remove the clutch disengage shaft (4) from the box. Disassemble the clutch disengage fork (2) from the transmission. Slide the clutch disengage bearing (1) and the support hub from the clutch disengage hub.

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Clutch - Clutch and components

Clutch - Troubleshooting Problem No movement when a gear is selected and the clutch pedal is let out.

With foot on the clutch pedal, engine speed raises but drive speed stays the same. It is very difficult to change gears.

Possible Cause Failure in rear axle or in transmission.

Clutch maladjustment. Thrust bearing is not moving. Chafing of friction disc. Pressure plate failure. Clutch disc slips.

Correction Connect differential lock. If tractor moves, failure is on differential outlet. If machine does not move, possible failure in transmission or in rear axle. Adjust clutch. • Check linkage. Replace friction disc. Repair or replace pressure plate. • Check clutch disc adjustment. • Chafing of clutch disc.

• Pressure plate failure. Clutch drag (does not let out completely). • Check clutch adjustment. • Chafing of clutch disc.

It is impossible to put in Clutch does not disengage. gear, engine stalls when machine is still, with foot on clutch pedal.

Noise due to transmission Chafing of thrust bearing. bell. Noise changes when putting foot on clutch pedal and letting it out. Chafing of clutch pilot bearing. Clutch does not engage Faulty clutch disc. gently. Faulty pressure plate. Chafing of clutch pilot bearing. Faulty flywheel.

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• Pressure plate failure. • Check clutch adjustment. • Chafing of clutch disc. • Jamming of clutch disc over flywheel, pressure plate or input shaft splines. • Pressure plate failure. Repair or replace pressure plate. Replace thrust bearing.

Replace clutch pilot bearing. Replace clutch disc. Replace pressure plate. Replace clutch pilot bearing. Check flywheel as detailed in engine section.

Index Clutch - 18 Clutch and components - 110 Clutch - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Clutch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Clutch - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Clutch - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Clutch - Install - PTO drive disc bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Clutch - Remove - PTO drive disc bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Clutch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Transmission

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.130] Mechanical transmission external controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.140] Mechanical transmission internal components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3 [21.112] Power shuttle transmission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.4 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.5

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Loctite® 515

Reference

PAGE

Mechanical transmission - General specification

21.1 / 8

Mechanical transmission external controls - Assemble - Shift levers and cover

21.2 / 7

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Transmission - 21 Mechanical transmission - 114

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21 Mechanical transmission - 114

TECHNICAL DATA Mechanical transmission General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Mechanical transmission Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exploded view 8X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exploded view - Shift lever position and circulation of forces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overview - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exploded view - Planetary gear set, Dual power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Exploded view - Direct drive clutch, Dual power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Exploded view - Reduction clutch, Dual power transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

SERVICE Mechanical transmission Service instruction - Component accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Inspect - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Assemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 End play - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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DIAGNOSTIC Mechanical transmission Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC TRANSMISSION OIL

Reference Mechanical transmission - General specification

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PAGE 21.1 / 8

Transmission - Mechanical transmission

Mechanical transmission - General specification Specification Available shims

Output shaft end play 0.038 - 0.086 mm (0.0015 - 0.0034 in) 0.076 mm (0.003 in) 0.127 mm (0.005 in) 0.305 mm (0.012 in) Lubricate 66 l (17.4 US gal)

Oil Capacity

For models with front wheel drive, increase the rear axle oil quantity by 1.2 l (1.3 US qt)

Dual power systems Planetary gear box end play Specification 0.1 - 0.51 mm (0.004 - 0.020 in) Available shims 0.33 mm (0.013 in) 0.81 mm (0.032 in) Allowed gap between 1.17 - 1.52 mm (0.046 - 0.060 in) planetary cover and Refer to the table below to determine required shims. housing Average calculated clearance Shim requirement 0.025 - 0.33 mm (0.001 - 0.013 in) â&#x20AC;˘ One 0.33 mm (0.013 in) shim 0.34 - 0.66 mm (0.013 - 0.026 in) 0.67 - 0.81 mm (0.026 - 0.032 in) 0.82 - 1.14 mm (0.032 - 0.045 in) 1.15 - 1.52 mm (0.045 - 0.060 in)

Dual power system pressure Lubrication system pressure

â&#x20AC;˘ One 0.81 mm (0.032 in) shim One 0.81 mm (0.032 in) shim Two 0.33 mm (0.013 in) shims One 0.33 mm (0.013 in) shim Gap within specification, shim not required

Pressure testing 15.2 - 17.9 bar (220.4 - 259.6 psi) 5.0 - 8.5 bar (72.5 - 123.3 psi)

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Transmission - Mechanical transmission

Mechanical transmission - Speeds Range Lever

Dual Power

Main Shift Lever 1

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Direct

Power

Transmis-

Wheel Speed

1500 RPM 1900 RPM 2100 RPM 2200 RPM sion Ratio 0.27 km/h (0.17 mph) 0.34 km/h (0.21 mph) 0.33 km/h (0.21 mph) 0.42 km/h (0.26 mph) 0.58 km/h (0.36 mph) 0.74 km/h (0.46 mph) 0.78 km/h (0.48 mph) 1.01 km/h (0.63 mph) 1.51 km/h (0.94 mph) 1.94 km/h (1.21 mph) 1.88 km/h (1.17 mph) 2.42 km/h (1.50 mph) 3.31 km/h (2.06 mph) 4.25 km/h (2.64 mph) 4.50 km/h (2.80 mph) 5.78 km/h (3.59 mph) 5.39 km/h (3.35 mph) 6.93 km/h (4.31 mph) 6.73 km/h (4.18 mph) 8.65 km/h (5.37 mph) 11.81 km/h (7.34 mph) 15.18 km/h (9.43 mph) 16.07 km/h (9.99 mph) 20.67 km/h (12.84 mph) 0.38 km/h (0.24 mph) 0.49 km/h (0.30 mph) 2.17 km/h (1.35 mph)

0.34 km/h (0.21 mph) 0.47 km/h (0.29 mph) 0.41 km/h (0.25 mph) 0.54 km/h (0.34 mph) 0.73 km/h (0.45 mph) 0.94 km/h (0.58 mph) 0.99 km/h (0.62 mph) 1.28 km/h (0.80 mph) 1.91 km/h (1.19 mph) 2.45 km/h (1.52 mph) 2.38 km/h (1.48 mph) 3.07 km/h (1.91 mph) 4.19 km/h (2.60 mph) 5.38 km/h (3.34 mph) 5.70 km/h (3.54 mph) 7.32 km/h (4.55 mph) 6.83 km/h (4.24 mph) 8.77 km/h (5.45 mph) 8.52 km/h (5.29 mph) 10.96 km/h (6.81 mph) 14.96 km/h (9.30 mph) 19.23 km/h (11.95 mph) 20.36 km/h (12.65 mph) 26.18 km/h (16.27 mph) 0.48 km/h (0.30 mph) 0.62 km/h (0.39 mph) 2.75 km/h (1.71 mph)

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0.37 km/h (0.23 mph) 0.48 km/h (0.30 mph) 0.46 km/h (0.29 mph) 0.59 km/h (0.37 mph) 0.81 km/h (0.50 mph) 1.04 km/h (0.65 mph) 1.10 km/h (0.68 mph) 1.42 km/h (0.88 mph) 2.11 km/h (1.31 mph) 2.72 km/h (1.69 mph) 2.64 km/h (1.64 mph) 3.39 km/h (2.11 mph) 4.63 km/h (2.88 mph) 5.95 km/h (3.70 mph) 6.30 km/h (3.91 mph) 8.10 km/h (5.03 mph) 7.55 km/h (4.69 mph) 9.70 km/h (6.03 mph) 9.42 km/h (5.85 mph) 12.11 km/h (7.52 mph) 16.63 km/h (10.33 mph) 21.25 km/h (13.20 mph) 22.50 km/h (13.98 mph) 28.93 km/h (17.98 mph) 0.53 km/h (0.33 mph) 0.68 km/h (0.42 mph) 3.04 km/h (1.89 mph)

0.39 km/h (0.24 mph) 0.50 km/h (0.31 mph) 0.48 km/h (0.30 mph) 0.62 km/h (0.39 mph) 0.85 km/h (0.53 mph) 1.09 km/h (0.68 mph) 1.15 km/h (0.71 mph) 1.48 km/h (0.92 mph) 2.21 km/h (1.4 mph) 2.84 km/h (1.76 mph) 2.76 km/h (1.71 mph) 3.55 km/h (2.21 mph) 4.85 km/h (3.01 mph) 6.23 km/h (3.87 mph) 6.60 km/h (4.10 mph) 8.48 km/h (5.27 mph) 7.91 km/h (4.92 mph) 10.16 km/h (6.31 mph) 9.87 km/h (6.13 mph) 12.69 km/h (7.89 mph) 17.32 km/h (10.76 mph) 22.27 km/h (13.84 mph) 23.57 km/h (14.65 mph) 30.31 km/h (18.83 mph) 0.56 km/h (0.35 mph) 0.72 km/h (0.45 mph) 3.18 km/h (1.98 mph)

67.08 52.18 53.75 41.81 30.63 23.82 22.50 17.50 11.74 9.13 9.41 7.32 5.36 4.17 3.94 3.06 3.29 2.56 2.63 2.05 1.50 1.17 1.10 0.86 46.47 36.30 8.17

Transmission - Mechanical transmission

Range Lever

Dual Power

Main Shift Lever A

Direct

Power

Direct

Wheel Speed

1500 RPM 1900 RPM 2100 RPM 2200 RPM 2.79 km/h (1.73 mph) 7.75 km/h (4.82 mph) 9.96 km/h (6.19 mph)

3.53 km/h (2.19 mph) 9.81 km/h (6.10 mph) 12.62 km/h (7.84 mph)

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3.90 km/h (2.42 mph) 10.85 km/h (6.74 mph) 13.95 km/h (8.67 mph)

4.09 km/h (2.54 mph) 11.63 km/h (7.23 mph) 14.61 km/h (9.08 mph)

Transmission Ratio 6.35 2.29 1.78

Transmission - Mechanical transmission

Mechanical transmission - Torque Component Clutch release bearing hub support bolts Clutch release fork bolt Front support plate bolts Gear shift cover assembly bolts Gear shift fork retaining screws Oil baffle/shift lever stop plates Output shaft retainer bolts Rear support plate retaining bolts Reverse idler shaft retaining bolt Neutral start switch

Specification 67 N·m 47 N·m 44 N·m 56 N·m 31 N·m 22 N·m 44 N·m 44 N·m 23 N·m 40 N·m

(49 lb (35 lb (32 lb (41 lb (23 lb (16 lb (32 lb (32 lb (17 lb (30 lb

ft) ft) ft) ft) ft) ft) ft) ft) ft) ft)

Dual power system Component Control valve spool cap Control valve body screws Planetary gear box screws Planetary gear cap fastening screws Lubrication tube connection Pressure control tube connection

Specification 38 N·m (28 lb ft) 44 N·m (32.5 lb ft) 105 N·m (77 lb ft) 47 N·m (35 lb ft) 17.5 N·m (12.9 lb ft) 12 N·m (9 lb ft)

Mechanical transmission - General specification Transmission and rear axle lubricant capacity Lubricant Sealants for gaskets Longitudinal Clearance of output shaft Shims available for the output shaft bearing retainer

56.8 l NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Sealant for NEW HOLLAND flexible gaskets. 82995770 ( 50 ml) and 82995771 ( 300 ml) 0.0254 - 0.0762 mm 0.0762 mm 0.1270 mm 0.3048 mm 0.7620 mm

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Transmission - Mechanical transmission

Mechanical transmission - Overview 8x2 The non-synchronised transmission is a constant gear type that allows eight forward and two reverse speeds, which are selected manually by means of two shift levers. The main lever manually selects among four forward speeds or one reverse speed, while the shorter reduction lever allows the operator to select the long or short connection. The transmission has a built-in safety start switch that only allows the engine to work if the reduction lever is in the neutral position. Shift lever positions (with an optional super reducer) L = LOW N = NEUTRAL C = SUPER-REDUCTION H = HIGH R = REVERSE

RCPH09TTS115AAD

The gears are constantly engaged and the connections are made by sliding couplings. The primary transmission shaft is on the upper shaft and the main counter-axle and the output axle are on the lower shaft. The transmission is equipped with a power take-off (PTO), which is independent of the transmission speeds and has one or two speeds. The transmission has straight cut gears. All bearings are roller bearings except for the output axle which has roller cone bearings. The movement of the output axle is controlled by the thicknesses between the output axle cap and the bearing retainer. Low pressure oil from the hydraulic system is used for pressure lubrication of the gear box. One part of the low pressure hydraulic oil is picked up by external tubes from the oil cooler located at the front of the machine. The cold oil then moves to the gearbox. The main counter-axle and the output axle are hollow and receive oil from the cooler. There are some transversal perforations in the main counter-axle and the output axle that allow the lubrication oil to come out and cool the shift gears. The return hydraulic oil passes through the gear box and goes back to the machineâ&#x20AC;&#x2122;s hydraulic system and differential box. Therefore, the gear box, differential box and hydraulic system make up a common oil deposit. The dual power option consists of a set of planetary gears directly installed between the clutch and the output axle in the standard transmission. The set of planetary gears allows the operator to directly select drive or reduction for each speed of the standard transmission.

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Transmission - Mechanical transmission

Mechanical transmission - Exploded view 8X2 A- Input Axle . 1. Clutch release bearing case support 2. O ring 3. Input axle retainer 4. Input axle fastening clip B- Upper axle (primary) . 1. Front bearing of multiple input gear 2. Lock washer – only with dual power 3. Multiple input gears C- Secondary counter-axle . 1. Snap Ring 2. Front bearing of secondary counter-axle D- Main counter-axle . 1. Main counter-axle front bearing 2. Snap Ring 3. Washer 4. Gears from 3rd to 7th 5. Coupling matched to connection, point 6 6. Coupling matched to connection, point 5 7. Gears from 1st – 5th 8. Washer 9. Reverse gear E- Output axle . 1. Cone bearing 2. Lubrication oil transfer tube 3. Coupling of long/short ranges 4. Output axle F- Covers . 1. Snap Ring 2. Snap Ring 3. PTO axle bearing 4. Snap Ring 5. PTO axle

5. Retainer 6. Input Axle 7. Retainer

4. Rear bearing of multiple input gear 5. Snap Ring 6. Connection of gears from 4th – 8th

3. Multiple gear of secondary counter-axle 4. Rear bearings of secondary counter-axle

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

Washer Coupling matched to connection, point 12 Coupling matched to connection, point 11 Gears from 2nd – 6th External bearing cup Cone bearing Counter-axle External bearing cup

5. Short range bearing 6. Shim 7. Cone bearing

6. 7. 8. 9.

External bearing cup Covers Shims Output axle retainer

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Transmission - Mechanical transmission

RCPH10TTS002HAF

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Transmission - Mechanical transmission

Mechanical transmission - Exploded view - Shift lever position and circulation of forces

RCPH10TTS001HAF

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Transmission - Mechanical transmission

Mechanical transmission - Overview - Dual power system The dual power system consists of a planetary gear set installed between the clutch and the input shaft of the transmission. The planetary gear set incorporates two hydraulically operated clutches that secure one or several elements of the planetary gear system to produce either the normal direct drive to the transmission or a reduced power drive (power under-drive). The power under-drive lowers the speed and increases torque.

Direct drive By fixing any two members of the planetary gear system, a direct drive is produced without changing either the speed or the direction of the turn. Upon compressing the direct drive clutch disengagement discs, the sun gear (3) is fixed to the carrier (2) of the planetary gears that operate as a member of the output system. When force is applied, the ring gear (1) turns the normal direct drive.

RCPH09TTS148AAD

RCPH09TTS453AAD

When the reduction clutch discs are compressed, the sun gear (4) is fixed to the planetary gear box. When force is passed to the ring gear (1), the planet gears (2) are made to turn on their own axis, so that they will “walk” around the sun gear and drag the planetary gear carrier (3). The planetary gear carrier is a member of the output system and turns in the same direction as the ring gear but at a slower speed, thus increasing torque. This is how power is produced in a reduction mode.

The dual power system is controlled though a two position valve located on one side of the planetary gear box. The valve routes the oil from the low volume side of the hydraulic system’s tandem pump to either the direct drive clutch port or the reduction clutch port. The pressure is regulated by the low pressure control valves and the system is protected against overpressure by the PT safety valve. Speeds by gear in direct drive are equal to those of an 8 speeds transmission.

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Transmission - Mechanical transmission

Oil circulation to the direct drive clutch

RCPH10TTS016GAF

Pressure oil 1. Pilot valve 2. Control Valve Spindle 3. Closing rings

4. Transmission input axle

Lubrication oil 8. Hub support plate 9. Direct drive clutch discs 10. Reduction clutch piston return spring 11. Sun gear

5. Direct drive clutch piston 6. Transmission countershaft 7. Direct drive clutch box

12. Central shaft 13. Ring gear and input shaft 14. Planetary gear

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Reservoir and exhaust oil 15. Planetary gear carrier 16. Planetary gear box 17. Reduction clutch disc 18. Reduction clutch piston return springs 19. Reduction clutch piston

Transmission - Mechanical transmission

The control valve, which has no neutral position, is moved through a solenoid-activated pilot valve. The solenoid is controlled by means of a switch located on the instrument panel. When the dual power control switch is changed to normal position (direct drive), the electric current goes through the solenoid of the control valve and activates the solenoid coil. Activating the solenoid makes the pilot valve close, preventing the oil that enters through the port "A" port from affecting the upper part of the control valve. However, the oil may pass through the center of the control valve and work under the control valve spool. When the oil pressure works under the control valve, it makes the spool go up, routing the oil between the fields to the corridor made in the planetary gear box that connects the direct drive clutch hub with the separation that exists between the second and third closing rings. This hub has a passage that lets the oil pass behind the direct drive clutch piston. The pressure moves the direct drive clutch piston, compresses the spring and fixes the direct drive clutch discs to connect the direct drive clutch. The hydraulic oil behind the reduction clutch piston comes out and returns through the control valve and the planetary gear box. The control valve oil also returns to the planetary gear box through a passage in the body of the control valve. When the direct drive clutch is connected, the planetary gear carrier is fixed to the sun gear, which is grooved to the direct drive clutch box. When any two members of the planetary gear set are joined, direct drive is produced without any change in the speed or direction of the turn. Therefore, as the planetary carrier and the sun gear remain joined, the force that enters through the ring gear passes directly to the planetary gear carrier, which is stretched by a connection axle to the transmission input.

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Transmission - Mechanical transmission

Oil circulation to the reduction clutch

RCPH10TTS017GAF

Pressure oil 1. Pilot valve 2. Control Valve Spindle 3. Closing rings

4. Transmission input axle

Lubrication oil 8. Hub support plate 9. Direct drive clutch discs 10. Reduction clutch piston return spring 11. Sun gear

5. Direct drive clutch piston 6. Transmission countershaft 7. Direct drive clutch box

12. Central shaft 13. Ring gear and input shaft 14. Planetary gear

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Reservoir and exhaust oil 15. Planetary gear carrier 16. Planetary gear box 17. Reduction clutch disc 18. Reduction clutch piston return springs 19. Reduction clutch piston

Transmission - Mechanical transmission

When the dual power control switch is moved to the power position (reduction), the electrical connection to the solenoid is cut and deactivated, thus leaving the pilot valve open. Now the oil from port "A" can work both at the upper surface and the lower surface of the control valve. However, as the upper surface of the control valve is superior to the lower one, the control valve comes down due to the greater force existing above. The oil from port "A" now passes through the control valve spool by means of a perforation in the planetary gear box to the reduction clutch piston. The pressure moves the piston, compressing the return springs and joining the reduction clutch discs; that is, connecting the reduction clutch. The hydraulic oil behind the direct drive piston returns through the control valve and the planetary gear box. The return oil of the control valve also goes to the planetary gear box through a perforation in the control valve box. As the support member in the output, it turns in the same direction but at a slower speed than the ring gear, thus producing a reduction. The result has a lower speed and more torque. When the reduction clutch is connected, the direct drive clutch is joined to the planetary gear box. Just as the sun gear is grooved to the direct drive clutch, the planetary gear box is also fixed. Upon applying force to the ring gear and sustaining the sun clutch, the planet gears of the planetary gear carrier turn on their own axis and â&#x20AC;&#x153;walkâ&#x20AC;? around the sun gear, dragging the carrier with them.

Circulation of lubrication oil The lubrication oil comes from the low pressure hydraulic system. This oil is routed by tubes toward the transmission oil cooler before entering a passage in the body of the control valve. This can be seen at port "B". Refer to the figure for the oil circulation for the direct drive clutch or the reduction clutch shown earlier. The oil circulates through passages in the planetary gear box between the first and second closing rings of the direct drive clutch hub and through a passage in line with the direct drive clutch discs. The oil circulates around the clutch discs and because the set of planetary gears turn, the oil lubricates the bearings and other components of the box. The oil from the bottom of the box goes through a tube that connects it with the bearings of the main counter-axle in the support plate of the tube. Excess oil from the box flows directly to the shift box to lubricate gears and bearings. The oil that enters into the support plate of the hub flows to the central passage of the counter-axle and lubricates the bearings and gears through perforations in the axle. As the components of the output counter-axle and axle turn, the oil passes to the input axle and multiple range gears lubricating the multiple range gears, the upper gears and the shift box bearings. The excess oil from the counter-axle flows directly into the shift box through a slot in the front support plate.

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Transmission - Mechanical transmission

Mechanical transmission - Exploded view - Planetary gear set, Dual power transmission

RCPH10TTS011FAF

(1) (2) (3) (4) (5)

Cap Thrust washer Sun gear Direct drive clutch Shaft

(6) Thrust washer (7) Planetary gear box (8) Reduction clutch (9) Planetary gear carrier (10) Pilot bearing

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(11) Ring gear and shaft assembly (12) Shim (13) Ring gear bearing

Transmission - Mechanical transmission

Mechanical transmission - Exploded view - Direct drive clutch, Dual power transmission

RCPH10TTS012FAF

(1) (2) (3) (4)

Steel plates Pressure plate Snap ring Friction plates

(5) (6) (7) (8)

Snap ring Spring retainer Piston return spring Sealing rings

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(9) Direct drive clutch box (10) Piston retainers (11) Piston

Transmission - Mechanical transmission

Mechanical transmission - Exploded view - Reduction clutch, Dual power transmission

RCPH10TTS013FAF

(1) Piston return springs (2) Pressure plate (3) Snap ring (4) Spring retainer

(5) (6) (7) (8)

Friction plate Rear plate Piston retainers Control valve body

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(9) Planetary gear box (10) Piston (11) Dowel pins

Transmission - Mechanical transmission

Mechanical transmission - Service instruction - Component accessibility Some components are only accessible once other components are removed. • While the transmission is installed, only these components are accessible: • Dual power control valve • Shift levers • Shift cap • Safety start switch • These components are accessible when the motor is removed: • All the components previously listed as accessible • Clutch • Clutch release shaft, fork and bearings • Dual power • Main input axle • Front bearings of upper front and internal axle • Front retainer • These components are accessible when the gearbox is removed: • All of the components previously listed as accessible • Rear cap • PTO drive axle • Selection rails, forks, stop components and blockers • Output axle • Multiple range gears • Upper front axle components • Reverse intermediate gear components

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Transmission - Mechanical transmission

Mechanical transmission - Disassemble 1. Separate the engine and the transmission. 2. Remove the shift cover. For detailed instructions, see Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130). 3. Remove the retaining bolt (3) for the clutch release fork (2). 4. Remove the clutch release shaft (4) from the casing. 5. Remove the clutch release fork from the transmission. 6. Slide the clutch bearing (1) and hub from the support.

RCPH09TTS122AAD

RCPH09TTS123AAD

RCPH09TTS125AAD

7. Disconnect the low pressure lines from the clutch release bearing hub support (1) and the front support plate (2). Remove the hub support.

8. Remove the snap ring (1) that retains the main drive input shaft (2) to the transmission main shaft and remove the input shaft.

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Transmission - Mechanical transmission

9. Remove the retaining bolts (2) for the front support plate (1) and remove the support plate from the housing. If necessary, drive the support plate from the housing using a suitable drift inserted into the main transmission compartment.

RCPH09TTS124AAD

RCPH09TTS126AAD

RCPH09TTS128AAD

RCPH09TTS129AAD

10. Use a puller (2) and a shaft protector (3) to remove the front bearing (1) from the countershaft.

11. Remove the snap ring (5), the thrust washer (4) and the hydraulic pump idler gear (3) located on the output shaft retainer.

12. Remove the retaining bolts (1) for the rear support plate (2). 13. Using a rubber or copper mallet, move the front end of the PTO drive shaft back. This will separate the rear support plate from the transmission casing. If necessary, use levers (1) to separate the rear support plate (2) from the casing and remove the plate with the rear PTO drive shaft (5). 14. Remove the snap ring (3) that secures the PTO drive shaft bearing (6) and drive the shaft and bearing out of the support plate. 15. Remove the bolts that secure the output shaft retainer to the rear support plate and remove the retainer (4) and shims from the rear support plates.

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Transmission - Mechanical transmission

16. Partially remove the secondary countershaft assembly (1) until the front bearing is out of the location. Lift the secondary countershaft to allow the output shaft assembly (2) to be removed from the rear compartment. 17. Remove the idler shaft.

RCPH09TTS130AAD

RCPH09TTS131AAD

18. Position the high/low sliding coupling on the rear part of the main countershaft.

19. Remove the four detent plungers (1) and springs (2). NOTE: The detent balls (3) are located below the springs and are collected with the shift rail removal.

RCPH09TTS103AAD

RCPH09TTS104AAD

20. Unscrew the neutral start switch (1) from the housing. 21. Loosen the locknut and remove the bolt locking the high/low range fork (2) to the shaft. 22. Remove the range lever connector (3) from the shaft and slide the rail out from the rear of the gearbox. 23. Place a clean cloth beneath the neutral start switch actuator housing. Take care to ensure the ball, spring and actuating dowel are collected from the housing and rail. 24. Lift the high/low shift fork from the rear compartment.

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Transmission - Mechanical transmission

25. Unscrew the locknut and retaining screw from the 1st - 5th/3rd - 7th shift fork (1) at the front of the shift rail. Drive the rail forward from the transmission casing, pushing the sealing plug out with the end of the rail. Remove the shift connector and fork. 26. Unscrew the locknut and retaining screws from the 4th - 8th shift fork (2) and connector (3) and push the shift rail rearwards from the transmission case. Remove the fork and connector. 27. Unscrew the locknut an retaining screw from the reverse/2nd - 6th shift arm (4) and connector and slide the top rail out rearwards. Lift the shift arm and the connector from the transmission housing.

RCPH09TTS104AAD

RCPH09TTS105AAD

RCPH09TTS106AAD

28. Remove the locknut and screw (1) that retains the reverse/2nd - 6th shift fork to the lower shift rail (4) and push out the rail rearwards. Remove the shift fork from the transmission casing. 29. Remove the interlock plungers from the cross bore in the transmission case. If necessary, remove the bore plug situated on the left-hand side to facilitate removal of the plungers. 30. Bend down the lock tab and remove the bolt (3) that secures the reverse idler shaft to the transmission case. 31. Drive the shaft out forwards and lift out the reverse idler gear (2). 32. Position a step plate in the bore at the rear of the main shaft. 33. Drive the shaft forwards, using a suitable drift, from the transmission case and remove the 4th - 8th coupling gear. 34. Use a puller tool and a step plate to remove the front bearing of the main countershaft. 35. Remove the snap ring (4) located behind the bearing and remove the thrust washer (2). 36. Side the main countershaft (3) rearwards and remove the gears (1), couplings and thrust washer. Store components in order of removal to aid in reassembly. NOTE: The inner and outer sections of the sliding couplings are matched during manufacture and should not be separated.

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Transmission - Mechanical transmission

Mechanical transmission - Inspect Prior operation: Mechanical transmission - Disassemble (21.114) 1. Inspect the PTO drive shaft and bearing assembly for damage or wear. Replace as required. • To remove the bearing, use a puller tool with a suitable attachment and a shaft protector. • To install the bearing, use a suitable length sleeve with a 37 mm (1.46 in) internal diameter and 44 mm (1.73 in) external diameter. 2. Inspect the output shaft retainer and rear bearing cup for damage or wear. Replace as required. • To remove the bearing cup from the retainer, use a suitable punch. • To install the bearing cup, use a step plate and the punch. 3. Inspect the output shaft assembly for damage or wear. Replace as required. • To remove the front pilot bearing (3), use a puller tool (1) with a suitable attachment (2) and a shaft protector (4).

RCPH09TTS136AAD

36087269

• To remove the rear bearing, gear, and thrust washer, use a puller tool with a suitable attachment and a shaft protector. • To install the rear bearing, align the flats of the thrust washer with the flats of the shaft and position the bearing on the output shaft. Then use a puller tool (1) with a suitable attachment (3), a shaft protector (5) and a sleeve (2) with a 40 mm (1.6 in) internal diameter and 50 mm (2.0 in) external diameter to pull the bearing (4) into position.

4. Inspect the secondary countershaft assembly for damage or wear. Replace as required. • To remove the rear bearing, use a puller tool with a suitable attachment and a step plate.

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Transmission - Mechanical transmission

• To remove the front bearing (2), place two steel rods (4) that are 4.6 mm (0.18 in) diameter and 51 mm (2 in) long into the holes in the driving gear. Then use the puller tool (1) with a suitable attachment (3) and a step plate (5) to push the bearing from the countershaft. • To install the front and/or the rear bearing, use a puller tool with a suitable attachment and a step plate.

RCPH09TTS109AAD

RCPH09TTS110AAD

RCPH09TTS111AAD

5. Inspect the front and rear bearings in the main shaft assembly for damage or wear. Replace as required. • To remove the rear bearing (3) for the main shaft, use a puller tool (1) with a suitable attachment (2) and a step plate (4). • To remove the front bearing for the main shaft, place two steel rods that are 4.6 mm (0.18 in) diameter and 51 mm (2.01 in) long into the holes in the driving gear. Then use the puller tool with a suitable attachment and the step plate. • To install the rear bearing, use a puller tool with a suitable attachment and a step plate. • To install the front bearing, use a puller tool with a suitable attachment, a step plate and a suitable length sleeve with 64 mm (2.5 in) internal diameter and 76 mm (3.0 in) external diameter. NOTE: Whenever removing or installing the front bearing for the main shaft, ensure the anti-spin washer is in good condition before assembling. 6. Inspect the oil seal for the PTO drive shaft that is located within the main shaft for damage or wear. Replace as required. • To install the oil seal, lightly grease the sealing lip and place the oil seal so that the sealing lip faces rearward. Use a step plate a suitable sleeve to drive the seal into place. 7. Inspect the main countershaft assembly for damage or wear. Replace as required. • To remove the rear bearing (4) from the countershaft, use a puller tool (1) with legs (6) and a suitable attachment (3), a ratchet (2) and a shaft protector tool (5).

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Transmission - Mechanical transmission

• Inspect the bearing cup for the output shaft that is located in the end of the main countershaft for damage, corrosion or wear. Replace as required. • To remove the bearing cup, use a suitable punch (1) inserted through the two holes (2) in the gear . • To install the bearing cup, use a puller tool and a step plate.

RCPH09TTS112AAD

RCPH09TTS114AAD

RCPH09TTS113AAD

• To install the rear bearing (2), use a puller tool (1) with a suitable attachment (3), a step plate (5) and a suitable length sleeve (4) with a 51 mm (2.01 in) internal diameter and 82 mm (3.23 in) external diameter.

• Inspect all the gears that mount on the main countershaft for damage or wear. With the gears on the countershaft, check the bushings for free play. Inspect the reverse idler gear and bushing assembly. Replace as required. • Inspect the rear bearing cup for the main countershaft for damage or wear. The rear bearing cup is situated in the transmission case. Replace as required. • To remove the rear bearing cup (1), use a slide hammer (2). • To install the rear bearing cup, use a suitable punch.

• Inspect the front bearing for the main countershaft for damage or wear. Replace as required. • Inspect all of the components with internal splines, external splines or gear teeth for damage or wear. Replace as needed during assembly. • Inspect the lubrication drillings for obstruction. 8. Inspect the gear shift forks, rails, arms and connectors for damage or wear. Inspect the detent on the shift rails and replace if worn.

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Transmission - Mechanical transmission

9. Inspect the transmission case. â&#x20AC;˘ Wash out the transmission case with a suitable solvent to remove all particles of metal and dirt. Dry with a clean, lint free cloth of compressed air. â&#x20AC;˘ Inspect the case for cracks or other damage. Replace as required. Next operation: Mechanical transmission - Assemble (21.114)

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Transmission - Mechanical transmission

Mechanical transmission - Assemble 1. Install the main countershaft through the rear compartment and assemble in the following sequence: 1.

2nd - 6th gear (connecting teeth forwards)

Reverse/2nd - 6th sliding couplings and connector

Phosphorous bronze thrust washer

Reverse speed gear (connection teeth rearward)

Phosphorous bronze washer.

1st - 5th gear (connecting teeth forwards)

3rd - 7the /1st - 5th sliding coupling and connector

3rd - 7th gear (connecting teeth back)

Thrust Washer

10. Snap Ring 11. Front bearing NOTICE: The connectors have a bevel on one side of the inside diameter. This bevel must face the rear part of the transmission to allow the connector to seat correctly on the main countershaft splines. The sliding coupling and connectors are matched during manufacture and should be installed with the etched marks aligned. 2. Support the main countershaft during reassembly and ensure the rear bearing seats squarely in the bearing outer track. 3. Position the high/low sliding coupling on the rear of the main countershaft. 4. Ensure the snap ring is positioned correctly. The snap ring retains the main shaft rear bearing in the transmission case. 5. Install the 4th - 8th coupling gear on the rear of the main shaft with the shift fork groove forwards. 6. Position the main shaft assembly in the transmission casing. 7. Drive the main shaft assembly rearwards to seat the rear bearing in the location within the casing. 8. Place the reserve idler gear (1) between the supporting lugs with the extended hub of the gear towards the front of the transmission. 9. Install the reverse idler shaft from the rear compartment with the retaining bolt hole forwards. Install the retaining bolt (2) and locktab. Tighten the retaining bolt to a torque of 23 NÂˇm (17 lb ft) and bend up the locktab.

RCPH09TTS105AAD

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Transmission - Mechanical transmission

10. Install the reverse/2nd - 6th (4) shift fork onto the appropriate sliding coupling on the main intermediate shaft. Install the lower shift rail (5) from the rear compartment with the fork retaining hole to the rear of the shift rail. Install the fork retaining screw and the lock nut. Tighten the retaining screw to a torque of 31 N·m (23 lb ft). 11. Insert the two interlock plunges into the bore from the left-hand side of the transmission case and install the plug. Place each plunger between the three shift rail bores. 12. Place the 4th - 8th shift fork (10) in the sliding coupling. Install the shift rail (1) from the rear, with the oil relief groove rearwards, and pass through the bore in the shift fork. Install the retaining screw and lock nut. Tighten the retaining screw to a torque of 31 N·m (23 lb ft). NOTE: When installing the remaining top shift rails, ensure the rails already installed are in the neutral position so the interlock plungers do not prevent the rail from entering the front support bore. 13. Place the lower end of the reverse/2nd - 6th shift arm (6) in the location hole the reverse/2nd - 6th shift fork (4). Slide the reverse/2nd - 6th (9) top shift rail in from the rear with the oil relief groove facing backwards. With the shift rail correctly located in the shift arm, install the remaining screw and lock nut. Torque each bolt to 31 N·m (23 lb ft). 14. Fit the 1st - 5th /3rd - 7th shift fork (3) in the sliding coupling located at the front of the main shaft. Install the 1st - 5th/3rd - 7th shift rail (2) in the front of the transmission. Insert the rail in the shift fork and secure with the retaining screw and lock nut. Install the shift connector to the rear of the rail and secure with the retaining screw and lock nut. Tighten each retaining bolt to a torque of 31 N·m (23 lb ft). Install the seal plug at the front end of the rail. 15. Place the high/low shift fork (7) in the groove of the high/low sliding coupling located on the output shaft. Install the high/low shift rail (8) in the shift fork. Secure the shift fork with the retaining screw and lock nut. Tighten the retaining screw to a torque of 31 N·m (23 lb ft). 16. Install the four shift rail detent balls, springs and plungers. Ensure the balls and plungers slide freely in the bores. 17. Ensure the snap ring located immediately in front of the secondary countershaft front bearing is in position in the transmission casing bore. 18. Hold the secondary countershaft assembly in position at the top of the rear compartment while installing the output shaft assembly. Align the secondary countershaft and drive forward until the front bearing seats against the locating snap ring in the transmission case.

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Transmission - Mechanical transmission

19. Place the rear support plate, without the output shaft retainer assembly, on the transmission rear face. Drive the plate into position on the dowels, then install the retaining bolts. Torque the bolts to 44 N·m (32 lb ft) 20. Install the PTO drive shaft and rear bearing through the rear of the transmission. Use a soft-faced mallet to drive the shaft and bearing into position. Secure the rear bearing with a snap ring. 21. Install shims between the rear support plate and the bearing retainer of the output shaft to obtain the specified end-play in the taper roller bearings of the output shaft. NOTE: Shims are available in thicknesses of 0.076 mm (0.003 in), 0.127 mm (0.005 in) and 0.305 mm (0.012 in). 1.

Install shims to obtain a thickness of 1.6 mm (0.06 in) and install the output shaft bearing retainer assembly on the rear support plate.

Install the four retaining bolts and tighten to a torque of 44 N·m (32 lb ft).

Place the plunger of a dial indicator gauge (3) against the end face of the output shaft (2). Lever the shaft in and out and note the end-play reading. If no end-play is registered, add additional shims to produce a gauge reading.

Remove the indicator gauge and the four retainer bolts. Withdraw the retainer (1) and shims.

Remove shims to obtain an end float between 0.038 mm (0.0015 in) and 0.086 mm (0.0034 in).

After obtaining the correct end-play, install the bearing retainer (with the oil slot to the top), shims, and bolts. Torque the bolts to 43 N·m (32 lb ft) Recheck end-play.

Install the hydraulic pump idler gear, thrust washer, and snap ring.

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22. Install the front support plate (1) and the retaining bolts (2) in the housing.

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Transmission - Mechanical transmission

23. Install the main drive input shaft (2) and install the snap ring (1) that retains the main drive input shaft to the transmission main shaft.

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24. Install the hub support and connect the low pressure lines from the clutch release bearing hub support (1) and the front support plate (2).

25. For machines with dual power transmissions: 1. Lift the dual power housing and install it in the transmission case. Ensure the anti-spin washer is located between the front gear and front bearing in the transmission main shaft. 2. Install the retaining bolts for the dual power housing. 26. Place the clutch bearing (1) and hub in the support. 27. Place the clutch release fork in the transmission. 28. Install the clutch release shaft (4) in the casing. 29. Install the retaining bolt (3) for the clutch release fork (2).

30. Install the shift cover. For detailed instructions, see Mechanical transmission external controls - Assemble - Shift levers and cover (21.130). 31. Join the engine and the transmission.

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Transmission - Mechanical transmission

Mechanical transmission - Disassemble - Dual power system Prior operation: ] Mechanical transmission - Remove (21.114) 1. Drain the oil from the transmission and the rear axle center housings. 2. Disconnect the wiring harness from the wire assembly at the plug connector located above the transmission bell-housing. It is not necessary to take the wire assembly out of the transmission plug. 3. Remove the large rubber plug from the transmission bell-housing and disconnect the lubrication and pressure control lines from the control valve body. 4. Unplug the cable (2) from the dual power solenoid (3). 5. Remove the bolts that secure the control valve body (4) to the planetary housing and remove the control valve body. 6. Remove the gasket from the control valve body. 7. Remove the pressure line connector (5) and the lubrication line connector (1) from the valve body and remove the o-ring seals from the connectors.

RCPH10TTS056BAF

8. Separate the engine from the transmission. 9. Disconnect the rod between the clutch pedal and the clutch release cross-shaft lever by removing the clevis pin at the lever end.

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Transmission - Mechanical transmission

10. Remove the clutch release fork retaining pin (5) that secures the fork (4) and remove the clutch release cross-shaft (6). 11. Remove the fork and the clutch release bearing assembly (3). 12. Remove the bolts (1) that secure the planetary cover (2).

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13. Remove the cover from the planetary housing. 14. Remove the gasket from the cover. 15. Remove the ring gear and shaft assembly from the housing. 16. Remove the planetary gear box, shaft, sun gear and direct drive clutch assembly as a complete unit. 17. If necessary, use a slide hammer (3) and a shaft puller (4) to remove the reduction gear set and the direct drive clutch (1) from the ring gear bearing when removing the ring gear. Place the shaft puller over the shaft (2). 18. If necessary, remove the pilot bearing from the shaft using a puller with a suitable attachment and a step plate.

19. Remove the shaft (2) and separate the planetary gear box (1) from the direct drive clutch (3). 20. Remove the sun gear (4) from the inner splines of the direct drive clutch.

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Transmission - Mechanical transmission

21. Remove the bolts (2) that secure the planetary housing (1) to the transmission case.

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22. Remove the planetary gear box from the case. Do not discard or lose the anti-spin washer. The anti-spin washer is located between the front gear and front bearing in the transmission main shaft and may come away when the dual power housing is removed. 23. Remove and discard the gasket on the rear hub of the planetary housing. 24. Remove the o-ring between the planetary gear box and the transmission front plate. 25. Remove the direct drive clutch assembly: 1.

Remove the sealing rings (1) from the rear hub of the direct drive clutch housing (2).

2. Depress the piston return spring and remove the snap ring (3) from the inner hub using a clutch compressor tool (4) with a puller tool or a press ram (1). 3. Release the pressure and ensure the spring retainer (2) does not enter the groove for the snap ring. 4. Remove the spring retainer and the piston return spring.

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Transmission - Mechanical transmission

5. Remove the snap ring (2)for the pressure plate. 6. Remove the pressure plate, the friction plates and steel plates from the clutch housing (1). Note the order of removal to aid in assembly.

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CAUTION Eye injury hazard! Wear protective goggles when using compressed air. Failure to comply could result in minor or moderate injury. C0035A

7. Remove the piston. â&#x20AC;˘ Place the direct drive clutch housing face down a bench. â&#x20AC;˘ Place an air nozzle in the hole between the middle and the rear grooves in the clutch housing hub and carefully blow out the piston.

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Transmission - Mechanical transmission

26. Remove the reduction clutch assembly: 1. Fabricate four restraining clamps, as shown.

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A. 50 mm (1.97 in) B. 34.3 mm (1.35 in) C. 20 mm (0.79 in) D. 54 mm (2.13 in)

E. 5 mm (0.20 in) F. 15 mm (0.59 in) G. 8 mm (0.31 in) H. 11 mm (0.43 in)

2. Equally space the restraining clamps (3) around the planetary housing rim and secure the clamps with the planetary housing bolts. 3. Remove the large snap ring (2) from the inner surface of the planetary housing (1). 4. After removing the snap ring, gradually release the pressure as you remove the restraining clamps.

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Transmission - Mechanical transmission

5. Remove the spring retainer (3), the pressure plate (2) and the friction plate (4). Note the order of removal to aid in assembly. 6. Remove the piston return springs (1), the dowel pins (6) and the rear plate (5).

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7. Remove the piston. â&#x20AC;˘ Place the reduction clutch housing face down a bench. â&#x20AC;˘ Place an air nozzle in the pressure supply port of the control valve housing and carefully blow out the piston. 8. Remove the inner and the outer piston seals. 27. Remove the control valve assembly: 1.

Remove the plug (2) from the control valve body (3).

Remove the solenoid (1) and pivot valve assembly.

Remove the control valve spool (4).

Next operation: Mechanical transmission - Inspect - Dual power system (21.114)

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Transmission - Mechanical transmission

Mechanical transmission - Inspect - Dual power system WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

Prior operation: Mechanical transmission - Disassemble - Dual power system (21.114) 1. Clean all parts in a suitable solvent and dry thoroughly with a dry, lint-free cloth or with compressed air. 2. Inspect the lubrication inlet tube, the pressure inlet tube and the lubrication oil tube for damage or distortion. Replace as required. 3. Inspect the control valve solenoid cable for damage or loose connections. 4. Inspect the clutch release hub (2) and bearing (4) for damage or wear. Replace as required. â&#x20AC;˘ To remove the bearing, use a puller tool (1) with a suitable attachment (3) and a step plate (5). â&#x20AC;˘ When installing the bearing, press the bearing onto the hub so that the thrust face of the bearing faces away from the shoulder on the hub.

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5. Pack the recess in the bearing hub bore with a high melting point grease. 6. Inspect the clutch release fork for damage or wear. Replace as required. 7. Inspect the cross-shaft and lever for damage or wear. If damage is present, install a new assembly. Inspect the shaft bushings for wear and replace as needed. When installing a new bushing, drive the bushing into the housing until the bushing is flush with the outside edges of the cross-shaft locating bores. 8. Inspect the planetary cover for damage or wear. Check the face of the cover and the mating surface for nicks or burrs and remove any imperfections with an abrasive stone. 9. Inspect the planetary carrier and gears, planetary shaft, pilot bearing and thrust washer for damage or wear. Replace as required. 10. Inspect the sun gear for excessive wear or damaged teeth.

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Transmission - Mechanical transmission

11. Inspect the sealing rings from the rear hub of the direct drive clutch assembly for damage, distortion or cracks. Replace as required. When installing a new seal: • Insert the seal in a 60 mm (2.36 in) internal diameter test bore for a period of 10 minutes before assembling. This procedure ensures the seals obtain the correct amount of pretension to avoid damage on assembly. • Use suitable grease to hold the seals in position. • Ensure the seal does not protrude above the lands of the direct drive housing. 12. Inspect the bore in the hub of the planetary housing where the direct drive sealing rings locate. Replace the planetary housing if excessive wear or damage is detected. 13. Inspect the direct drive clutch housing both externally for cracks or damage and internally for wear and piston scuffing. Inspect the housing external splines for cracked, broken or missing teeth. 14. Inspect the direct drive clutch piston, friction plates, steel plates, pressure plate and snap ring and install new piston seals. 15. Inspect the direct drive clutch piston return spring, spring retainer and snap ring for damage. 16. Inspect the thrust washer for damage or distortion. 17. Inspect the planetary housing for cracks or damage. Inspect the reduction clutch piston, dowel pins, springs, rear plate, friction plate, pressure plate, spring retainer and snap ring and install new piston seals. Discard and replace any cracked, damaged or badly worn parts. 18. Inspect the front bearing (4) for the transmission input shaft located in the of the planetary housing hub (3). • To remove the bearing, use a puller tool (2) and a slide hammer (1). • Press in a new bearing.

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19. Inspect the ring gear and shaft assembly for damage or wear. Inspect the shaft splines for damage. If necessary, install a new ring gear and shaft assembly.

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Transmission - Mechanical transmission

20. Inspect the ring gear bearing (2) for wear or damage. Replace as required. â&#x20AC;˘ To remove the bearing, use a puller tool (6) with legs (5) and a suitable attachment (4) and use a step plate (1). Take care not to damage the shim located behind the bearing. â&#x20AC;˘ To install the bearing, place the shim against the step on the ring gear shaft (3). Press the bearing onto the shaft using a sleeve of suitable length that has a 82.6 mm (3.25 in) internal diameter and a 95.3 mm (3.75 in) external diameter. RCPH09TTS165AAD

NOTICE: The shim located behind the ring gear bearing governs the planetary gear set end play. If any of the major components of the planetary gear set are changed, refer to Mechanical transmission - End play - Dual power system (21.114) to determine the correct size shim to be installed. 21. Inspect the valve spool bore in the valve body for damage or wear. 22. Inspect the valve spool lands for scratches, wear or other damage. Remove minor burrs or scratches with a fine abrasive material. Clean and dry prior to reassembly. 23. Inspect the solenoid for cracks or damage. if any doubt exists as to the serviceability of this component, replace with a new solenoid assembly. Next operation: Mechanical transmission - Assemble - Dual power system (21.114)

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Transmission - Mechanical transmission

Mechanical transmission - Assemble - Dual power system Prior operation: Mechanical transmission - Inspect - Dual power system (21.114) 1. Assemble and install the control valve assembly: 1.

Install the control valve spool (4).

Install the solenoid (1) and pivot valve assembly.

Insert the plug (2) in the control valve body (3).

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2. Assemble and install the reduction clutch assembly: 1.

Install the piston (7) and the piston inner and outer seals (6).

Install the piston return springs (1), the dowel pins (8) and the rear plate (5).

Install the spring retainer (3), the pressure plate (2) and the friction plate (4).

4. Install the large snap ring (2) in the inner surface of the planetary housing (1). 5. Equally space the restraining clamps (3) around the planetary housing rim and secure the clamps with the planetary housing bolts. Ensure the snap ring is correctly seated. 6. Gradually release the pressure as you remove the restraining clamps.

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Transmission - Mechanical transmission

3. Assemble and install the direct drive clutch assembly: 1.

Install the piston (6) and the piston seals (4) in the clutch housing (5).

Install the pressure plate (2), the friction plates (3) and the steel plates (1).

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3. Install the snap ring for the pressure plate.

4. Install the spring retainer (2) and the piston return spring (1).

5. Depress the piston return spring and install the snap ring (3) in the inner hub. 6. Release the pressure and ensure the spring retainer (2) and the snap ring are seated correctly.

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Transmission - Mechanical transmission

7. Install the sealing rings (1) in the rear hub of the clutch housing (2).

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4. Install the o-ring between the planetary gear box and the transmission front plate. 5. Install a new gasket on the rear hub of the planetary housing. 6. Install the planetary gear box (1) on the transmission case. Ensure the anti-spin washer is located between the front gear and front bearing in the transmission main shaft. Secure with the bolts (2).

7. Install the thrust washer and the shaft (2) in the planetary gear box (1). 8. Install the sun gear (4) in the inner splines of the direct drive clutch (3) and install the direct drive clutch.

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Transmission - Mechanical transmission

9. Install the thrust washer, the planetary carrier (4) and the pilot bearing (5). 10. Install a suitable shim (6) and the ring bearing gear (1) on the ring gear and shaft assembly (3). Install the ring gear and shaft assembly onto the shaft. NOTICE: A new shim is required if you are installing a new cover, bearing, ring gear, planetary carrier, sun gear, direct drive clutch or planetary gear box. For detailed instructions on how to determine the correct shim, refer to Mechanical transmission - End play - Dual power system (21.114). 11. Install a new gasket on the cover (2) for the planetary gear box and install the cover. NOTICE: The cover should easily seat in the gear box with all of the components install. Do not force the cover. If the cover does not seat correctly, remove and reassemble the components of the gear box.

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RCPH09TTS152AAD

12. Secure the cover (2) with the bolts (1). 13. Install the clutch release bearing assembly (3), the clutch release cross-shaft (6), fork (4) and fork retaining pin (5).

14. Install the rod between the clutch pedal and the clutch release cross-shaft lever and secure with the clevis pin at the lever end. 15. Join the engine and the transmission.

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Transmission - Mechanical transmission

16. Attach the pressure line connector (5) and the lubrication line connector (1) to the control valve body and install new o-ring seals for the connectors. NOTE: Always install new o-rings. Coat all tube joints with a proprietary sealing compound. 17. Install a new gasket on the control valve body (4). 18. Install the control valve body to the planetary housing and secure with the bolts. 19. Attach the cable (2) to the dual power solenoid (3).

RCPH10TTS056BAF

20. Connect the lubrication and pressure control lines to transmission bell-housing and install the rubber plug. Ensure the rubber plug fits firmly in place over the solenoid wire. 21. Connect the wiring harness for the wire assembly at the plug connector located above the transmission bell-housing. 22. Add oil to the transmission and the rear axle center housings. Next operation: Mechanical transmission - End play - Dual power system (21.114)

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Transmission - Mechanical transmission

Mechanical transmission - End play - Dual power system Prior operation: Mechanical transmission - Assemble - Dual power system (21.114) The shim located between the bearing and the step on the ring gear shafts determines the end play between the components of the planetary gear box. End play specification is 0.1 - 0.851 mm (0.004 - 0.034 in). NOTICE: The end play needs to be adjusted if you will be installing a new cover, bearing, ring gear, planetary carrier, sun gear, direct drive clutch or planetary gear box. 1. Install sun gear in the inside grooves of the direct drive clutch. 2. Place the thrust washer on planetary gear carrier and align the grooves. 3. Install the planetary gear carrier and the thrust washer in the sun gear and ensure the grooves of the planetary gear carrier interlock with the friction discs of the direct drive clutch. 4. Keeping the components together, mount the planetary gear axle from behind. If necessary, tap the axle to ensure full engagement. 5. Place the pilot bearing inside the axle using a sleeve with a 41.2 mm (1.62 in) inside diameter and a 47.8 mm (1.88 in) outside diameter. 6. Place the planetary gear box (with the reduction clutch mounted) on the workbench. NOTE: Place the planetary gear box on blocks so that the rear part of the planetary gear axle does not touch the workbench when the direct drive clutch and planetary gears are installed. 7. Place the thrust washer in the gear box with the tab pointed up and towards the rear part of the transmission. 8. Install the direct drive clutch and the set of planetary gears in the gear box. Check that the assembly is set firmly in the gear box. 9. Install the ring gear and shaft assembly (without ring gear bearing or shim) in the gear box. Place the ring gauge tool on the step of ring gear axle. 10. Place the cover on the planetary gear box without the gasket. NOTICE: Check that all components are set firmly in the gear box. 11. Measure the distance between the face of the cover and the face of the gear box in three equal points and intervals. â&#x20AC;˘ If the average of the three measures is between 1.17 - 1.52 mm (0.05 - 0.06 in), a shim is not needed. The measurement is within specification. â&#x20AC;˘ If the average measurement is lower than specified above, a different shim is required. See . 73403953 04/04/2014

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Transmission - Mechanical transmission

12. Remove the cover, the ring gear and axle from the planetary gear box. Take out the ring hub and place the correct shim on the step of the ring gear axle. Put the bearing in ring gear using a sleeve of suitable length that has a 82.6 mm (3.3 in) internal diameter and a 95.3 mm (3.8 in) external diameter. 13. Take out the planetary gear box components and keep them in order for final assembly. See Mechanical transmission - Assemble - Dual power system (21.114) . Next operation: Mechanical transmission - Install (21.114)

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Transmission - Mechanical transmission

Mechanical transmission - Remove Splitting the engine and the front transmission shaft WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

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1. Drain the cooling system (see cooling system drainage in the cooling chapter in the engine section). 2. Disconnect the negative battery lead (1). 3. Use an appropriate cable to connect a block and tackle to the front weights and remove them (if installed).

4. Remove the exhaust protection plate bolts (1). Remove the plate.

5. Remove the clamp (1) and disconnect the exhaust from the turbo charger. 6. Remove the exhaust support fixing bolts (2).

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Transmission - Mechanical transmission

7. Remove the exhaust support fixing bolts ( (1), (2) and (3)). Remove support.

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8. Disconnect the positive battery lead (1) from the starter engine.

NOTE: Note the position of the oil coolant hoses. 9. Loosen the clamps (1) and disconnect the oil coolant hoses.

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Transmission - Mechanical transmission

10. Disconnect engine electric harness connectors.

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NOTE: Note the position of the steering cylinder oil feed hoses. 11. Disconnect the steering cylinder intake hoses (1).

12. Loosen the fixing lock (1) and remove the throttle control rod to the injection pump.

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13. Disconnect the fuel feed and return lines (1) from the fuel tank.

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Transmission - Mechanical transmission

14. Remove the front wheel drive driveshaft shield. 15. Expand and slide the lock ring (1) and the sleeve (2) over the front wheel drive driveshaft.

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16. Remove the front wheel drive driveshaft and the central support.

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Transmission - Mechanical transmission

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17. Position the splitting kit (4) 297471 under the tractor. 18. Use the supports (3) in the splitting kit to support the transmission on the platform for splitting. 19. Remove the lower fixing bolts from the engine to the transmission. 20. Remove the two rear sump fixing bolts on the left side. Repeat this operation for the right side. 21. Install the adapter plate (1) 380000844 and the trestles to support the engine (2) 297617 between the engine and a cart for splitting. 22. Position wooden wedges (1) between the front axle and the front support. This prevents axle articulation.

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Transmission - Mechanical transmission

23. Check if all necessary hoses and electric connectors have been disconnected. It may be necessary to disconnect additional items due to other optional equipment that was installed on the tractor. 24. Check once more if the engine and transmission are safely supported on the platform for splitting. Remove the fixing bolts from the engine to the transmission. 25. Remove the front support and the engine from the transmission.

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Transmission - Mechanical transmission

Mechanical transmission - Install Installation of the engine and front support to the transmission 1. Align the front support and engine assembly with the transmission and install the fixing bolts from the engine to the transmission. Tighten to the specified torque value. 2. Remove the kit to split the tractor.

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3. Install the front wheel drive driveshaft and the central support.

4. Expand and slide the lock ring (1) and the sleeve (2) over the front wheel drive driveshaft. 5. Install the front wheel drive driveshaft shield.

6. Connect the fuel feed and return lines (1) to the fuel tank.

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Transmission - Mechanical transmission

7. Install the throttle control rod to the injection pump and connect the fixing lock (1).

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8. Connect the steering cylinder intake hoses (1).

9. Connect engine electric harness connectors.

10. Connect the oil coolant hoses and tighten the clamps (1).

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Transmission - Mechanical transmission

11. Connect the positive battery lead (1) to the starter engine.

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12. Install the exhaust support and fasten it with the bolts ( (1), (2) and (3)).

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13. Install the exhaust support fixing bolts (2). 14. Connect the exhaust to the turbo charger. Install the clamp (1).

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Transmission - Mechanical transmission

15. Install the exhaust protection plate and fasten with the bolts (1).

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16. Use an appropriate cable to connect a block and tackle to the front weights and install them (if installed).

17. Connect the negative battery lead (1). 18. Fill the cooling system (see filling the cooling system in the cooling chapter in the engine section). 19. Top up the hydraulic system with the correctly specified oil.

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Transmission - Mechanical transmission

Mechanical transmission - Service instruction Introduction to transmission servicing General The division of processes within this section facilitates the servicing of the 8 x 2 transmission, minimizing the need for disassembly. The processes are divided into five groups as described below with components specified that may appear in each group. GROUP 1: Assemblies seen with the transmission installed. • Shift covers, including levers, forks and mechanism. • Neutral safety starting switch. • AFWD outlet assembly and solenoid. • Clutch lock. GROUP 2: Assemblies seen at the front of the transmission, with engine and transmission both removed — Servicing. • Clutch bearing and hydraulic tube assembly. • Front cover, including seals and reverse idler gear. • Inlet shaft and bearing. • Forward/reverse synchronizer. • Reverse cog. GROUP 3: Assemblies seen at the rear of the transmission, with the rear axle and transmission both removed — Servicing. • Power take-off shaft, bearing and sealant. • High and medium ranges synchronizer. • Low-range sleeve. • Gears and bearing group. • Output shaft assembly. GROUP 4: Assemblies seen with the transmission removed from the tractor — full servicing. • Transmission shaft assembly, including 3rd and 4th synchronizer. • Counter shaft assembly, including 1st and 2nd synchronizer. • AFWD shaft and bearings. GROUP 5: Component inspection and repair (sub-assembly servicing).

Servicing internal transmission components Whenever servicing the transmission, work in clean environments and with clean tools. Clean the transmission box to prevent dirt from entering.

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Transmission - Mechanical transmission

Use lint-free cloths to clean the parts and your hands. Spread out the clean parts over a clean sheet of paper for a thorough inspection. Do not use force when installing transmission components. If it is not possible to assemble the parts with ease, examine them to find the cause of the difficulty or apply a film of lubricating oil to facilitate assembly. Lubricate all shafts, bearings, oil sealant and gears with a film of clean lubricant before installing them in the transmission.

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Transmission - Mechanical transmission

Mechanical transmission - Check Transmission components General inspection and repair Inspect the retainers and sealing rings for damage and wear. Always install new assemblies. Apply a thin film of new transmission oil to the sealant surface before assembling. Clean the bearings with a solvent appropriate for cleaning and inspect. If wear is evident or a bearing does not turn freely, replace with a new one. Inspect the gears for wear and damage or broken teeth. Inspect the shafts for wear and ensure the oil chambers are not obstructed. Replace any gears or shafts that are worn or damaged. If any tapered bearing or track is not in good condition, replace the entire assembly. If the transmission housing was completely disassembled, clean it on the inside and outside. Inspect the housing for damage or fractures. Before assembling components on the transmission, make sure the components are clean and free from contamination. When assembling the components, lubricate the bearings and shafts with new lubricant oil.

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Transmission - Mechanical transmission

Mechanical transmission - Install NOTE: If you need to install a new cover, bearing, ring gear, planetary transporter, sun gear, direct action clutch or planetary housing, see Mechanical transmission - End play - Dual power system (21.114) , before installing the planetary components in the transmission box. Pay special attention to the following points: 1. If all the components have been installed correctly, the cover should fit easily into its housing. If force is required, it indicates incorrect assembly. 2. Install new sealing rings in the lubricating oil transfer tube. 3. Grease all the tube unions with a sealing compound. 4. Install new sealing rings in the control valve pressure line and lubrication line connections. 5. Take care to avoid damaging the control valve solenoid and wire. Make sure that the rubber ring is firmly in its place to protect the solenoid wire.

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Transmission - Mechanical transmission

Mechanical transmission - Troubleshooting 7630 8030

LA LA

Problem Low pressure only in direct drive

Possible Cause Snap ring for the direct drive clutch is displaced. Gasket for the control valve body is damaged or leaks. Leaks at the sealing rings for the hub of the direct drive clutch or wear is present on the dual power housing. Leaks at interior or exterior seals of piston for the direct drive clutch. Piston or housing for direct drive clutch is broken or cracked. Low pressure only during Gasket for the control valve body is damreduction aged or leaks. Leaks at interior or exterior seals of piston for the reduction clutch . Piston for the reduction clutch is broken or cracked. Low pressure in direct Failure in the low pressure hydraulic circuit. drive and in reduction High pressure in direct Failure in the low pressure hydraulic circuit. drive and in reduction Rear wheels do not move Low pressure in the direct drive clutch circuit. when direct drive is connected (the reduction drive works) Direct drive clutch piston is damaged, scratched or bent. Control valve spool is stuck in reduction position. Direct drive clutch discs are worn out or defective. Pressure plate snap ring of the direct drive clutch is broken or outside its lodging place. Rear wheels do not Low pressure in the reduction clutch circuit. move when reduction is connected (the direct drive works) Reduction clutch piston is damaged, scratched or bent. Control valve spool is stuck in direct drive position. Reduction clutch discs are worn out or defective. Low pressure in the dual power system. Rear wheels do not move in direct drive or in reduction Defects in ring gear of planetary gear set, planetary gear carrier, sun gear or main shaft splines. Problem in the shift box or differential box. Clutch problem. Engine jams or bounces The piston for the direct drive clutch is when switching from scratched, damaged or bent. direct drive to reduction The piston return springs of the direct drive clutch are broken or defective.

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Correction Replace snap ring and any other damaged part. Replace gasket. Replace sealing rings and/or dual power housing. Replace seals. Replace piston or housing. Replace gasket. Replace seals. Replace piston. Troubleshoot the hydraulic system. Troubleshoot the hydraulic system. Troubleshoot low pressure in the direct drive clutch. Refer to Mechanical transmission - Low pressure - Dual power system only (21.114). Replace piston. Check control valve spool. Replace clutch discs. Install snap ring correctly or replace the snap ring. Troubleshoot low pressure in the reduction clutch. Refer to Mechanical transmission - Low pressure - Dual power system only (21.114). Replace piston. Check control valve spool. Replace clutch discs. Check system pressure. Check components needed.

and

Check and repair as needed. Repair clutch. Replace piston. Replace springs.

replaces

Transmission - Mechanical transmission

Problem Engine jams or bounces when switching from reduction to direct drive

Low pressure of lubrication High pressure of lubrication

Possible Cause Correction Direct drive clutch discs are bent or defec- Change clutch discs. tive. The piston for the reduction clutch is Replace piston. scratched, damaged or bent. The piston return springs of the reduction clutch are broken or defective. Reduction clutch discs are bent or defective. Spring of cooler/lubrication valve is broken or loose or the valve is stuck open. Oil cooler is plugged or covered. Spring of lubrication/cooler valve is stuck open.

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Replace springs. Change clutch discs. Repair cooler/lubrication valve. Replace oil cooler. Repair cooler/lubrication valve.

Index Transmission - 21 Mechanical transmission - 114 Mechanical transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Mechanical transmission - Assemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Mechanical transmission - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Mechanical transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Mechanical transmission - Disassemble - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Mechanical transmission - End play - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Mechanical transmission - Exploded view - Direct drive clutch, Dual power transmission . . . . . . . . . . . . . . . . . . . . 19 Mechanical transmission - Exploded view - Planetary gear set, Dual power transmission . . . . . . . . . . . . . . . . . . . 18 Mechanical transmission - Exploded view - Reduction clutch, Dual power transmission . . . . . . . . . . . . . . . . . . . . . 20 Mechanical transmission - Exploded view - Shift lever position and circulation of forces . . . . . . . . . . . . . . . . . . . . . 12 Mechanical transmission - Exploded view 8X2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Mechanical transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mechanical transmission - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical transmission - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Mechanical transmission - Inspect - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Mechanical transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Mechanical transmission - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Mechanical transmission - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Mechanical transmission - Overview - Dual power system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Mechanical transmission - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Mechanical transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Mechanical transmission - Service instruction - Component accessibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Mechanical transmission - Speeds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mechanical transmission - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical transmission - Troubleshooting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Transmission - 21 Mechanical transmission external controls - 130

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21 Mechanical transmission external controls - 130

FUNCTIONAL DATA Transmission housing cover Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Mechanical transmission external controls Disassemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Inspect - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Assemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Transmission housing cover Transmission housing cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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CONSUMABLES INDEX Consumable LoctiteÂŽ 515

Reference Mechanical transmission external controls - Assemble - Shift levers and cover

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PAGE 21.2 / 7

Transmission - Mechanical transmission external controls

Transmission housing cover - Exploded view Top cover set

LAIL11TS0001F0A

1. Starter inhibitor switch wire harness 2. Shift cover bolt 3. Washer 4. Boot 5. Gasket 6. Pin 7. Spring 8. Ball 9. Spring 10. Pin 11. Plate retaining bolt 12. Baffle plate

13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24.

Washer Washer Range lever (high / low) Gear lever Pin, starter inhibitor switch Dowel pin Lever fixing pins Keeper Lever spring Seal Brake Gear lever button.

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Disassemble - Shift levers and cover CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Remove the floor plate. 2. Place the shift levers in the neutral position. 3. Disconnect the negative (ground) battery cable. 4. Disconnect the connector for the neutral start switch from the wire harness. 5. Remove the retaining bolts for the shift cover and partially lift the cover from the transmission housing. 6. With the shift cover raised, disconnect the neutral start switch wires from the switch. 7. Remove the shift cover, with the shift lever fasteners, and the gasket from the transmission. 8. Remove the retaining screws for the oil cut-off plate and remove the plate. 9. Remove the washers between the oil cut-off plate and the shift levers. 10. Unscrew and remove the shift cap screws. 11. Carefully cut and remove the snap ring from the shift levers. For example, place the shift lever in a vice before removing the snap ring to prevent the snap ring from dangerously ejecting from the grooves on the shift levers. 12. Remove the retainers and springs from the shift levers. 13. Remove the shift levers. Next operation: Mechanical transmission external controls - Inspect - Shift levers and cover (21.130)

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Inspect - Shift levers and cover WARNING Chemical hazard! Always wear protective clothing and goggles when cleaning with solvents, acids, or alkaline chemical agents. Always follow the chemical manufacturer's instructions. Failure to comply could result in death or serious injury. W0180A

CAUTION Eye injury hazard! Wear protective goggles when using compressed air. Failure to comply could result in minor or moderate injury. C0035A

Prior operation: Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130) 1. Wash the shift levers and cover assemblies in a suitable solvent. Dry with a clean, lint free rag or use compressed air. 2. Inspect the shift cover for cracks or other damage. Replace as needed. 3. Inspect the shift lever retainers for damage or wear. Replace as needed. 4. Inspect the oil cut-off plate for damage or wear. Replace as needed. 5. Inspect the shift levers for damage or wear, including the grooves for the snap rings. Replace as needed. 6. Inspect the springs for cracks or distortion. Replace as needed. 7. Inspect the shift cap screws for damage or wear. Replace as needed. 8. Inspect the wiring harness for the neutral start switch for damage or wear. Replace as needed. Next operation: Mechanical transmission external controls - Assemble - Shift levers and cover (21.130)

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Assemble - Shift levers and cover Prior operation: Mechanical transmission external controls - Inspect - Shift levers and cover (21.130) Prior operation: Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130) 1. Apply a 2 mm bead of LOCTITEÂŽ 515 gasket eliminator to the transmission mating surface of the transmission shift lever cover. 2. Install the shift cover, with the shift lever retainers. 3. Reconnect the neutral start witch wires to the switch. Ensure the neutral start actuator housing aligns with the locating pin in the shift cover. 4. Secure the shift cover with the retaining bolts. Tighten the retaining bolts to a torque of 56 NÂˇm (41 lb ft). 5. Install the oil cut-off plate and secure with the retaining screws. 6. Install the washers on the oil cut-off plate and place the shift levers in the washer. 7. Route the shift levers through the shift lever fasteners on the cover plate. 8. Install the retainers and springs on the shift levers. 9. Install new snap rings on the shift levers. 10. Screw on the shift cap screws. 11. Ensure the shift levers are in the neutral position. 12. Reconnect the negative (ground) battery cable. 13. Install the floor plate.

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Check Inspecting and repairing 1. Inspect the bushings and the forks. If there is evidence of wear or excessive play between the components, replace parts as needed. 2. Check the lubrication and support channels for obstruction to allow for proper lubrication.

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Transmission - Mechanical transmission external controls

Mechanical transmission external controls - Assemble Assemble in the reverse order of the disassembly process. Smear some grease on the shafts and bushings as they are being assembled.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Remove Gear shift cover and levers Removal 1. Put the shift levers into neutral. 2. Disconnect the negative battery lead. 3. Disconnect the starter motor inhibitor switch wire from the harness connection. 4. Remove the gear shift lever cover retaining bolts and partially raise the transmission box cover. With the cover lifted, disconnect the gear shift lever switch wires and remove the transmission shift assembly.

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LAIL11TS0009A0A

LAIL11TS0010A0A

Transmission - Mechanical transmission external controls

Transmission housing cover - Disassemble Disassemble 1. Remove the oil deflector plate retaining bolts on the lower side of the shift cover and remove the plate and the washers. 2. Remove the lever retaining brakes. If possible, place the gear shift lever on a vise as close as possible to the brake. After, with a punch, split the brakes lastly. During this operation make sure the retaining segments are not hazardously ejected from the lever grooves. Carefully disengage the vise and remove the springs, ball retainers and levers. NOTE: There is no need to remove the lever retaining pins from the cover set due to the levers being grooved.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Inspect Inspection 1. Wash out the gear cover and gear lever assemblies with a good solvent and dry with either a lint-free cloth or with compressed air. 2. Inspect the gear cover for fractures or other damages, replace the cover when necessary. 3. Inspect the ball seats on the gear lever and the ends for wear and the cover lever fixing pins. Replace worn or damaged pins. The new pins must be placed on the cover with pressure. 4. Inspect the starter switch wire harness for damage. Replace the harness when necessary.

Transmission box Wash the transmission box with an appropriate solvent to remove all the metal particles and impurities. Dry with a clean, lint free cloth of compressed air. Check the box for fractures or other damage, and if it is beyond repair assemble the transmission components in a new box.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Assemble 1. Lubricate the ball seats with good quality grease and pass the gear shift levers through the cover. 2. Fit the ball retainers and springs, compress the springs and fit the new holding brake. 3. Refit the two baffle washers on the lower side of the gearbox cover, the oil baffle plate and the holding bolts.

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Transmission - Mechanical transmission external controls

Transmission housing cover - Install 1. Fit the new seal on the gearbox cover and hold it in place with grease to facilitate assembly. 2. Refit the cover by following the assembly procedure in reverse and ensuring the following: â&#x20AC;˘ Ensure that the immobiliser actuator housing is aligned with the localisation pin on the gearbox cover. â&#x20AC;˘ Tighten the cover fixing bolts to 5.6 kgf (12.35 lbf)

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Index Transmission - 21 Mechanical transmission external controls - 130 Mechanical transmission external controls - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Mechanical transmission external controls - Assemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Mechanical transmission external controls - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical transmission external controls - Disassemble - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mechanical transmission external controls - Inspect - Shift levers and cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Transmission housing cover - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Transmission housing cover - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Transmission housing cover - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transmission housing cover - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission housing cover - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transmission housing cover - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Transmission - 21 Mechanical transmission internal components - 140

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21 Mechanical transmission internal components - 140

FUNCTIONAL DATA Gears, shaft, and bearings Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Transmission shaft Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Transmission internal parts Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

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Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Exploded view Exploded view

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Synchroniser assembly 1. 2. 3. 4. 5.

Clutch body Synchroniser brake Coupling sleeve synchroniser body Clutch body

6. 7. 8. 9.

Synchroniser brake Spring Guide Data

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Transmission - Mechanical transmission internal components

Gears, shaft, and bearings - Static description Synchroniser operation In the neutral position the data are pushed against the â&#x20AC;&#x153;Vâ&#x20AC;? shaped recesses in the coupling sleeve. The gears can turn freely on the shaft. bolt. When the coupling sleeve moves from neutral to the gear to be selected the synchroniser brake is forced against the gear body. Any speed difference in the parts to be coupled causes the synchroniser brakes to rotate. This rotation is limited by backstops and forces the synchroniser brake chamfered teeth against the coupling sleeve, preventing sleeve movement. The increase in pressure makes the synchroniser and clutch body eventually rotate at the same speed, synchronised with the shaft and gear speeds. After synchronisation, there is no friction between the clutch body and the synchroniser brake. The power on the chamfered teeth of those components is reduced, allowing the coupling sleeve to go past the synchroniser brake and link up to the gear teeth.

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Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble Prior operation: Mechanical transmission - Remove (21.114) 1. Separate the engine and the transmission. 2. Remove the shift cover. For detailed instructions, see Mechanical transmission external controls - Disassemble - Shift levers and cover (21.130). 3. Remove the retaining bolt (3) for the clutch release fork (2). 4. Remove the clutch release shaft (4) from the casing. 5. Remove the clutch release fork from the transmission. 6. Slide the clutch bearing (1) and hub from the support.

RCPH09TTS122AAD

RCPH09TTS123AAD

7. For machines with dual power transmissions: A. Remove the retaining bolts for the dual power housing. B. Lift the dual power housing and remove from the transmission case. Do not discard or lose the antispin washer. The anti-spin washer is located between the front gear and front bearing in the transmission main shaft and may come away when the dual power housing is removed. 8. Disconnect the low pressure lines from the clutch release bearing hub support (1) and the front support plate (2). Remove the hub support.

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Transmission - Mechanical transmission internal components

9. Remove the snap ring (1) that retains the main drive input shaft (2) to the transmission main shaft, and remove the input shaft.

RCPH09TTS125AAD

RCPH09TTS124AAD

RCPH09TTS126AAD

RCPH09TTS128AAD

10. Remove the retaining bolts (2) for the front support plate (1) and remove the support plate from the housing. If necessary, drive the support plate from the housing using a suitable drift inserted into the main transmission compartment.

11. Use a puller (2) and a shaft protector (3) to remove the front bearing (1) from the countershaft.

12. Remove the snap ring (5), the thrust washer (4) and the hydraulic pump idler gear (3)located on the output shaft retainer. 13. Remove the retaining bolts (1) for the rear support plate (2).

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Transmission - Mechanical transmission internal components

14. Using a soft faced mallet, drive the forward end of the PTO drive shaft rearwards. This will separate the rear support plate from the transmission casing. If necessary, use levers (1) to separate the rear support plate (2) from the casing and remove the plate with the rear PTO drive shaft (5). 15. Remove the snap ring (3) that secures the PTO drive shaft bearing (6) and drive the shaft and bearing out of the support plate. 16. Remove the bolts that secure the output shaft retainer to the rear support plate and remove the retainer (4) and shims from the rear support plates. RCPH09TTS129AAD

RCPH09TTS130AAD

RCPH09TTS131AAD

17. Partially remove the secondary countershaft assembly (1) until the front bearing is out of the location. Lift the secondary countershaft to allow the output shaft assembly (2) to be removed from the rear compartment. 18. Remove the secondary countershaft.

19. Remove the high/low sliding coupling from the rear of the main countershaft.

20. Remove the four detent plungers (1) and springs (2). NOTE: The detent balls (3) are located below the springs and are collected with the shift rail removal.

RCPH09TTS103AAD

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Transmission - Mechanical transmission internal components

21. Unscrew the neutral start switch (1) from the housing. 22. Loosen the locknut and remove the bolt locking the high/low range fork (2) to the shaft. 23. Remove the range lever connector (3) from the shaft and slide the rail out from the rear of the gearbox. 24. Place a clean cloth beneath the neutral start switch actuator housing. Take care to ensure the ball, spring and actuating dowel are collected from the housing and rail. 25. Lift the high/low shift fork from the rear compartment. RCPH09TTS104AAD

RCPH09TTS104AAD

RCPH09TTS105AAD

26. Unscrew the locknut and retaining screw from the 1st - 5th/3rd - 7th shift fork (1) at the front of the shift rail. Drive the rail forward from the transmission casing, pushing the sealing plug out with the end of the rail. Remove the shift connector and fork. 27. Unscrew the locknut and retaining screws from the 4th - 8th shift fork (2) and connector (3) and push the shift rail rearwards form the transmission case. Remove the fork and connector. 28. Unscrew the locknut an retaining screw from the reverse/2nd - 6th shift arm (4) and connector and slide the top rail out rearwards. Lift the shift arm and the connector from the transmission housing. 29. Remove the locknut and screw (1) retaining the reverse/2nd - 6th shift fork to the lower shift rail (4) and push out the rail rearwards. Remove the shift fork from the transmission casing. 30. Remove the interlock plungers from the cross bore in the transmission case. If necessary, remove the bore plug situated on the left-hand side to facilitate removal of the plungers. 31. Bend down the lock tab and remove the bolt (3) that secures the reverse idler shaft to the transmission case. 32. Drive the shaft out forwards and lift out the reverse idler gear (2). 33. Position a step plate in the bore at the rear of the main shaft. 34. Drive the shaft forwards, using a suitable drift, from the transmission case and remove the 4th - 8th coupling gear. 35. Use a puller tool and a step plate to remove the front bearing of the main countershaft.

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Transmission - Mechanical transmission internal components

36. Remove the snap ring (4) located behind the bearing and remove the thrust washer (2). 37. Side the main countershaft (3) rearwards and remove the gears (1), couplings and thrust washer. Store components in order of removal to aid in reassembly. NOTE: The inner and outer sections of the sliding couplings are matched during manufacture and should not be separated.

RCPH09TTS106AAD

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Transmission - Mechanical transmission internal components

Transmission shaft - Disassemble Transmission output to the AFWD assembly â&#x20AC;&#x201D; Disassemble 1. Carefully remove the dust guard cover from the AFWD output shaft bearing. 2. Remove the lock ring from the front bearing (7). Use a universal extractor and an appropriate shaft protector (4) to extract the front bearing (3), Figure 1.

LAIL11TS0355A0A

LAIL11TS0356A0A

LAIL11TS0357A0A

LAIL11TS0358A0A

3. Raise the spring box assembly (4) and the spring assembly (5) to connect the AFWD and slide the front half of the clutch (3) out of the shaft (1) and the rear half of the clutch (2), Figure 2.

4. Remove the lock ring from the rear bearing (21), Transmission shaft - Exploded view (21.140), using a universal extractor and an appropriate shaft protector (4), then extract the rear bearing (3) Figure 3. 5. Remove the rear half/gear of the clutch and take out both bearings, r (15) and (17) using two spacer rings (16) and (19) from the AFWD output shaft, Transmission shaft - Exploded view (21.140).

6. The oil transfer tube supplies oil under pressure to disconnect the AFWD clutch. This transfer tube is installed with interference in the transmission housing. It must be removed and the polyamide lock washer must be replaced. Remove the tube (3) by tightening the M10x1.5 bolt in the centre of the tube, then use a conventional sliding hammer and an appropriate adaptor to remove the tube, Figure 4.

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Transmission - Mechanical transmission internal components

Transmission shaft - Check AFWD output assembly â&#x20AC;&#x201D; Inspection. Refer to the cross section view, Transmission shaft Sectional view (21.140), to make component identification easier. 1. Inspect all the lock rings and the respective recesses for deformation and damage. 2. Inspect the internal drive shaft gear, the shaft front gear and the clutch half gear and examine the teeth for wear or cuts. 3. Carefully inspect all the bearings for wear or other damage. 4. Install new internal and external sealants, references (12) and (25), Transmission shaft - Sectional view (21.140), on the output shaft. 5. Carefully remove the output shaft sealant (19), Transmission shaft - Sectional view (21.140), from the cover and install a new sealant with an appropriate sealant installer or an adaptor. Replace the "O" seal. 6. Inspect the clutch spring assembly for split spirals or deformation. See the spring height under load, as shown in Figure 1, or compare it with a new part. If in doubt, replace the spring assembly. 7. Inspect the clutch front half internal surfaces for damage, making sure the sealing area is not scratched. 8. Examine the clutch engagement teeth for damage and wear. 9. Inspect the splined areas on the clutch front half, the output shaft and the internal shaft for damage and scratches. LAIL11TS0359A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble AFWD output shaft assembly 1. See Transmission shaft - Sectional view (21.140) for the cross section representation to help with assembly and observe the following references, giving them due attention. 2. Reassemble the AFWD output transfer assembly following the disassembly process in reverse order. 3. Apply transmission oil to the shaft sealants before proceeding with assembly and allow time for them to expand before assembling the sliding clutch half. 4. Use an appropriate press and a sleeve to install the front and rear bearings, making sure while installing the front one that the sliding clutch half, the spring assembly and its protection plate are not out of alignment, which may damage the sealants. 5. Ensure that the two washers (11), Transmission shaft - Sectional view (21.140), are placed on both sides of the driven half of the clutch. 6. For the clutch teeth to work correctly, it is essential that the pilot valve assembly (8), Transmission shaft - Sectional view (21.140), is fitted with the ball facing backwards.

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Transmission - Mechanical transmission internal components

Transmission shaft - Remove Disassembling the transmission gears assembly 1. On the front of the transmission, remove the two hydraulic system pipes from the clutch bearing, Figure 1. 2. Remove the bearing hydraulic assembly (2), (three bolts), Fig. 1. 3. Remove the front plate assembly (1), (eight bolts), Fig. 1. To make it easier to disassemble, use an appropriate punch through the top cover opening up to the front cover rear face. Gradually tap the cover near the guide pins until the cover comes loose. NOTE: The reverse idler gear, front cover oil pipe and transmission input shaft are also removed in this operation. LAIL11TS0661A0A

LAIL11TS0660A0A

LAIL11TS0662A0A

LAIL11TS0663A0A

4. Remove the lock ring from the secondary shaft (top). Move the reverse gear assembly slightly forwards and slide the inverter synchroniser assembly, Figure 2.

5. Slide out the reverse gear, Figure 3.

6. Remove the reverse gear group assembly, Figure 4.

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Transmission - Mechanical transmission internal components

7. Remove the oil distributor, Fig. 5. Take due care not to damage the guide pins that hold the distributor in position and ensure efficient lubrication of the assembly.

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LAIL11TS0665A0A

8. Remove the lock ring from the secondary shaft front bearing, Figure 6.

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Transmission - Mechanical transmission internal components

Transmission shaft - Remove Disassembling the transmission gear assembly components 1. Remove the lock ring from the rear of the secondary shaft assembly, (that holds the3rd and4thsynchroniser). 2. Pull the secondary shaft back and away (2), Fig. 1.

LAIL11TS0592A0A

LAIL11TS0593A0A

LAIL11TS0594A0A

3. Remove the main shaft (1) from the front of the box and remove the3rd and4th synchroniserand the 2ndgear (splined), from the side of the transmission. 4. Remove the secondary shaft front end lock ring (2). 5. Slide out the secondary shaft assembly (4) through the rear of the transmission housing, Figure 2. 6. Remove the following as an assembly (through the side opening): • 3rdgear (5) • 2ndgear (3) • 1stand 2ndsynchroniser assembly (2) • 1stgear (1) 7. Remove the lock ring that holds the idler shaft front bearing inside the housing and extract the bearing.

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Transmission - Mechanical transmission internal components

Transmission shaft - Remove Disassemble the AFWD output assembly and the transmission shaft 1. Remove the AFWD output assembly lock ring, Figure 1.

LAIL11TS0560A0A

LAIL11TS0561A0A

LAIL11TS0562A0A

2. To make disassembling easier, use an appropriate lever, supporting it on the points indicated on the cover, to remove the assembly, Figure 2.

3. Remove the lock ring from the front end of the shaft that holds the front gear assembly (3), Figure 3. 4. Remove the external lock ring that holds the rear bearing (2), Figure 3. 5. Remove the lock ring from the recess on the front part of the rear gear (1). Leave the lock ring hanging on the shaft, Figure 3. NOTE: Remove the shaft and the rear bearing as an assembly through the rear of the transmission. 6. To remove the front bearing from the AFWD output shaft, remove the four bolts that attach the shaft bearing support assembly to the housing transmission. Remove both lock rings from the bearing and push it out.

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Transmission - Mechanical transmission internal components

Transmission shaft - Install Installing the AFWD shaft 1. Install the front shaft bearing on the support assembly and fasten with the lock rings on both sides. 2. Install the support on the transmission housing and fasten with the four bolts. 3. Make sure the lock ring behind the rear bearing is fitted on the transmission housing. 4. Place the AFWD gear between the shaft support assembly and the housing. 5. Make sure the rear lock ring is fitted to the shaft. Position and fasten the rear bearing on the shaft. Pass the shaft and the bearing through the rear of the housing, securing it onto the rear gear and its front lock ring, front bearing and front gear. Install the front gear lock ring. NOTE: Take care not to damage the front bearing rollers when installing the shaft. 6. Fasten the rear bearing with the external lock ring (on the housing).

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Transmission - Mechanical transmission internal components

Transmission shaft - Install Installing transmission central components 1. Place the lock ring in the recess of the transmission opening (front idler shaft). 2. Install the front idler shaft needle bearing through the front of the transmission housing. 3. Place the parts below in succession through the side opening, as shown in Figure 1. • 1st speed gear • 1st and 2nd synchroniser assembly • 2nd speed gear • 3rd speed splined gear. • Engage the 1st and 2nd gear with the synchroniser. 4. Slide the idler shaft (4) from the rear through the parts installed in the previous operation. Push in the shaft fully, install the washer and fasten with the lock ring. 5. Install the secondary shaft (1) with the front bearing already assembled through the front of the transmission holding the 1st and 2nd gear assemblies and complete with the 3rd and 4th synchroniser (3), Figure 2.

LAIL11TS0451A0A

LAIL11TS0452A0A

LAIL11TS0453A0A

6. Align the shaft bearing with the housing opening and push it in enough to install the lock ring, Figure 3. 7. Fasten the gears and the synchronisers to the secondary shaft with the rear lock ring. 8. Pull the secondary shaft assembly slightly backwards and locate the assembly on the front bearing, install a wooden wedge between the AFWD shaft and one gear on the secondary shaft to hold it in position. Push the shaft forwards so it is in contact with the front bearing. 9. Install the needle bearing on the rear of the secondary shaft assembly (2), Figure 2.

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Range gear group Install the front bearing and shim on the upper range gear group with a press, Figure 1. Reducer gears group 1.

Rear bearing

Gear group

Shim

Front bearing

LAIL11TS0564A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Main shaft assembly Install the bearing (11) on the main shaft assembly using an hydraulic press, Figure 1. Main shaft: 1.

Lock ring

3rd and 4th synchroniser

3rd gear

2nd gear

Bearing

Shaft

Lock ring

Inverter synchroniser

Reverse gear

LAIL11TS0455A0A

10. Oil distributor 11. Bearing

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Auxiliary front wheel drive (AFWD) idler shaft 1. Fit the lock ring (6) onto the shaft, Fig. 1. 2. Install the rear bearing (9) and the lock ring (7), Fig. 1.

LAIL11TS0266A0A

3. Install the front bearing (3) on the transmission housing, Figure 1. 1. 2. 3. 4. 5.

Lock ring Output shaft gear Front bearing (installed on the front support) Lock ring Shaft driven gear

6. 7. 8. 9. 10.

Housing shaft Lock ring fixing the bearing to the shaft Housing lock ring Rear bearing Axle

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Power take off drive shaft assembly 1. Fit the lock ring (5) onto the shaft, Fig. 1. 1.

Sealant

Shaft

Lock ring

Bearing

Lock ring

2. Press on the bearing (4) and fasten into position with the lock ring (3), Figure 1. 3. Slide the sealant up to the shaft thrust face. LAIL11TS0456A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Reverse gear group assembly 1. Install the lubrication tube (4), Figure 1. It is very important that this stud is installed correctly as it allows for the flow of oil to lubricate the front bearing. 2. Install the bearings with interference using a press and appropriate adaptors. Reverse gear group: 1. Front bearing 2. Gear group 3. Rear bearing 4. Lubrication pipe LAIL11TS0621A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Reverse idler gear assembly 1. Assemble the gear (8) and thrust rings on the shaft and fasten with the lock rings (7) and (10). 2. Fasten the gear and the shaft assembly onto the front cover with the bolt and washer and a new “O” seal. Reverse idler components: 1. Bolt 2. Washer 3. “O” seal 4. Oil transfer pipe 5. Shaft 6. Washer 7. Lock ring 8. Idler gear 9. Washer

LAIL11TS0281A0A

10. Lock ring 11. Front plate

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Output shaft assembly 1. Install the components indicated below on the shaft following the sequence described here: Low range coupling sleeve (6), low range gear (5), thrust ring (4), spacer (3), roller bearing and cover (2). Ensure that the coupling sleeve slides freely on the shaft and that the gear also turns freely. 2. Install the tapered bearing and its cover (7).

LAIL11TS0267A0A

Output shaft components 1. 2. 3. 4. 5.

Shaft Rear bearing Spacer Thrust ring Low/medium range gear

6. 7. 8. 9.

Low range coupling sleeve Front bearing High and medium synchroniser Range gear

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Main idler shaft 1. Install the bearing (6) with a press or an appropriate beater. 2. Install the bearing cup (5). Idler shaft assembly 1.

3rdgear

1stgear

1stand 2ndsynchroniser

2ndgear

Bearing cup

Bearing

Shaft

LAIL11TS0670A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Assemble Input shaft 1. Install the rear shaft bearing (1) on the shaft (2). 2. Install the retainer (3) on the rear of the shaft. Lubricate the surfaces before assembly. Input shaft components 1.

Bearing

Shaft

Power take off (PTO) shaft retainer

LAIL11TS0457A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - Install Range gear group components (rear of the transmission) 1. Make sure the washer (1) has been fitted on the range assembly, Fig. 1. Install the assembly securing the shaft needle bearing and engage the3rd and4thsplines. 2. Assemble the medium gear with the high and medium range synchroniser. 3. Insert the gear and synchroniser assembly through the rear side opening and connect with the idler shaft splines.

LAIL11TS0372A0A

LAIL11TS0373A0A

NOTE: It may be necessary to push the AFWD gear slightly backwards, removing the external lock ring from the bearing. Ensure that the lock ring is fitted in its place before installing the output shaft. 4. Install the output shaft assembly (2), connecting it to the previously installed assembly (1), Figure 2. 5. Install the rear bearing to the range gear group. Heat up the bearing to a maximum temperature of 125 Â°C and push until it is in contact with the lip of the gear. 6. Assemble the rear cover assembly on the transmission housing (10 bolts). 7. Temporarily install the retainer over the output shaft on the rear cover in order to keep the output shaft in position.

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Transmission - Mechanical transmission internal components

Transmission shaft - Install Front components 1. Fully install the oil distributor assembly on the secondary shaft in the housing opening, Figure 1. Align the guide pins with the transmission holes. Check and make sure the lubricating hole is aligned. 2. Install the inverter gear group assembly. DO NOT INSTALL fully. 3. Slide the reverse gear and the inversion synchroniser assembly onto the secondary shaft. 4. Once the synchroniser is in contact with the shaft splines, move the synchroniser and the reverse gears group into place. NOTE: If needed, shift the synchroniser into the forward gear position to allow for assembly. After correctly assembling, put into neutral.

LAIL11TS0262A0A

LAIL11TS0263A0A

5. Fasten the components with the lock rings. 6. Apply appropriate chemical bond (sealant) between the front cover and the gasket and between the gasket and the transmission casing. Ensure a perfect seal. 7. Install the input shaft assembly and the reverse idler gear in the front cover. Fasten the idler shaft with the retaining bolt and install a new â&#x20AC;&#x153;Oâ&#x20AC;? seal. NOTE: Install the cover on the transmission, Figure 2, making sure the oil pipe from the front cover to the transmission housing is correctly positioned. Fasten the cover with the eight retaining bolts. 8. Assemble the clutch hydraulic actuator assembly and fasten with three bolts. 9. Install the hydraulic pipes.

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Transmission - Mechanical transmission internal components

Transmission shaft - Install AFWD output 1. If the unit features AWFD, place the AFWD transfer assembly oil feed pipe, complete with the Polyamide thrust sealant, in the transmission housing. The pipe is installed with interference in the housing. Install carefully using an appropriate punch. 2. Place the AFWD clutch quick action valve with the ball side facing backwards. Use an appropriate punch to firmly tap the rear part of the valve against the oil chamber in the AFWD shaft to ensure a perfect oil seal during operation. Fasten the valve with petroleum jelly.

LAIL11TS0668A0A

LAIL11TS0669A0A

3. Align the AFWD output assembly gear with the drive gear in the transmission housing and install, Figure 1. 4. Install the AFWD cover and fasten with the lock ring, Figure 2. A reinforced pair of pliers is recommended.

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Transmission - Mechanical transmission internal components

Transmission shaft - Install Power take off shaft 1. Lubricate and slide the power take off shaft assembly sealant up to the shaft lip. 2. Install the power take off shaft on the transmission, Figure 1. Fasten with the lock ring.

LAIL11TS0454A0A

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Transmission - Mechanical transmission internal components

Transmission shaft - End play Transmission output shaft longitudinal play The transmission output shaft longitudinal play should be between 0.0254 mm and 0.0762 mm. Perform the procedure below to check the play: 1. Remove the retainer assembly fastened into place with two bolts. 2. Install a few shims, Figure 1, of known dimensions and refit the retainer, tightening it to the specified torque. 3. Rotate the transmission several turns to position the assembly in place. 4. Install a calibration gauge (2) perpendicular to the end of the output shaft, Figure 2. 5. Use a lever (1) to measure the transmission play by moving the transmission components back and forth, Figure 2. LAIL11TS0264A0A

LAIL11TS0265A0A

6. The difference between the measured play and the specification is the thickness of the shims required to correctly adjust the transmission longitudinal play. NOTE: Increasing shim thickness increases longitudinal play. Reducing the shims reduces play. 7. Install the output shaft bearing retainer making sure the oil slit is facing upwards (TOP). 8. Check if the components below turn freely: • Input shaft • Power take off shaft • Output shaft • AFWD shaft 9. Check for play between the gears and on the synchronisers. 10. Check if all synchronisers are in neutral. 11. Install a new gasket on the top cover and assemble it with the forks in neutral on the transmission assembly. Fasten using eight bolts. Assemble the neutral start switch after tightening the cover. 12. Put the forks in neutral, fit the (forward) speed cover and fasten it using the ten bolts. Always use a new gasket. 13. Place the range assembly cover (rear) following the same procedure used for the gearshift cover. Apply the specified torque to the eight fixing bolts. 14. Install the AFWD pipe assembly onto the gearshift cover.

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Transmission - Mechanical transmission internal components

Transmission internal parts - Inspect Shift lever mechanism Check the shift lever forks, guards, arms and connectors for wear or distortion. Check the shift guard detains and replace the guards if the detains are worn. Check the box for fractures or other damage, and if it is beyond repair assemble the transmission components in a new box.

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Index Transmission - 21 Mechanical transmission internal components - 140 Gears, shaft, and bearings - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gears, shaft, and bearings - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Transmission internal parts - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Transmission shaft - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Transmission shaft - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Transmission shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Transmission shaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Transmission shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Transmission shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Transmission shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Transmission shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Transmission - 21 Power shuttle transmission - 112

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21 Power shuttle transmission - 112

SERVICE Power shuttle transmission Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power shuttle transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 73403953 04/04/2014

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Transmission - Power shuttle transmission

Power shuttle transmission - Service instruction E46 - OPEN CIRCUIT FROM FUSE 21

BRAG11TRCNH0227

BRAG11TRCNH0220

BRAG11TRCNH0210

BRAG11TRCNH0221

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Transmission - Power shuttle transmission

BRAG11TRCNH0222

BRAG11TRCNH0223

BRAG11TRCNH0224

BRAG11TRCNH0225

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Transmission - Power shuttle transmission

BRAG11TRCNH0226

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Transmission - Power shuttle transmission

Power shuttle transmission - Service instruction LA LA LA LA

7630 [Z7CA27168 - ] 7630 8030 [Z7CA27168 - ] 8030

E24 - SYNCHRONISER AND CLUTCHES REQUIRE CALIBRATION Calibrate spring pressure in both clutches

EHI - CLUTCH B NOT CALIBRATED Calibrate the clutch spring pressure in the Direct clutch (C2).

ELO - CLUTCH A NOT CALIBRATED Calibrate the clutch spring pressure in the Reduced clutch (C1). NOTE: These failures only occur after the installation of a new electronic module or after an "H8" (clean the electronic module memory functioning).

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Transmission - Power shuttle transmission

Power shuttle transmission - Service instruction 7630 [Z7CA27168 - ] 7630 8030 [Z7CA27168 - ] 8030

LA LA LA LA

E49 - WHEEL SPEED SENSOR OPEN CIRCUIT OR SHORT TO GROUND

BRAG11TRCNH0228

BRAG11TRCNH0233

BRAG11TRCNH0232

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Transmission - Power shuttle transmission

Power shuttle transmission - Service instruction 7630 8030

LA LA

E56 - SHUTTLE LEVER FORWARD SWITCH INPUT VOLTAGE HIGH

BRAG11TRCNH0215

Electronic Module Connector C127 (red).

BRAG11TRCNH0216

Electronic Module Connector C128 (black)

BRAG11TRCNH0231

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Transmission - Power shuttle transmission

BRAG11TRCNH0229

BRAG11TRCNH0230

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Transmission - Power shuttle transmission

Power shuttle transmission - Service instruction 7630 8030

LA LA

E26 - ENGINE RPM TOO HIGH E27 - ENGINE RPM TOO LOW

BRAG11TRCNH0235

BRAG11TRCNH0216

BRAG11TRCNH0234

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Index Transmission - 21 Power shuttle transmission - 112 Power shuttle transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power shuttle transmission - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power shuttle transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power shuttle transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Power shuttle transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

(*) See content for specific models 73403953 04/04/2014

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Transmission - 21 Creeper - 160

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Transmission - 21 Creeper - 160

TECHNICAL DATA Creeper General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Creeper Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Creeper Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 73403953 04/04/2014

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Transmission - Creeper

Creeper - General specification Reduction ratio Set of output axles with reduction gears Preload of output axle with reduction gears (pull necessary to turn output axle with a cord wound around the grooves of the output axle) Available shims

10.0:1 0.038 - 0.086 mm (0.001 - 0.003 in) 1.0 - 1.8 N (0.2 - 0.4 lb)

0.10 mm (0.0039 in) 0.15 mm (0.0059 in) 0.50 mm (0.0197 in)

Creeper - Torque 7630 8030

LA LA

Fastening screws of rear support plate Allen screws of output axle retainer

47 N·m (35 lb ft) 31 N·m (23 lb ft)

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Transmission - Creeper

Creeper - Overview The reduction gear box is optional in the non-synchronized 8x2 transmission with or without dual power. The reduction gear box allows an extra reduction in the ratio under the low standard range. The reduction is obtained through a set of planet gears located in the transmission output axle. Once installed, the reduction gear box allows an additional range of super shorts in four forward and three reverse speeds, thus increasing the total number of speeds available to twelve forward and three reverse speeds. In transmissions with dual power, another eight forward and two reverse speeds are obtained, increasing the total number of speeds available to twenty-four forward and six reverse speeds. There are alternative gears for reduction, either 5.7:1 or 10.0:1. Basically, all reduction gear boxes have a set of planet gears mounted in place of the transmission output axle of a normal box. The set of planet gears is made up of the following: • One external ring gear related to the shift box. • Planetary gears mounted on the carrier. The teeth on the rear part engage with the external ring gear. • The carrier, which has teeth on the outside diameter, takes the place of the output axle. • The intermediate ring gears engage the teeth on the front part of the planetary gears. • The coupling, which is grooved to and drives the output axle, can connect with the carrier or intermediate gear ring. • The coupling is moved by means of a selector fork In the neutral position as shown in Figure 1, the coupling does not engage any set of reduction gears and this way the coupling and the output shaft cannot be driven. • The low transmission range is selected by sliding the gear fork rod backward to the detent position adjacent for neutral. The rod movement through the fork makes the coupling engage the reduction gear set conveyor. Now the energy from the secondary counter shaft is transmitted through the conveyor and the coupling to the output shaft. The conveyor has the same number of teeth in the external diameter as the output shaft used in the normal transmission, therefore, the ground speeds obtained in the low range are identical to those of the normal transmission. • The reduced range is selected by sliding the gear shift rod and the fork further back to the final detent position. The coupling is moved by the fork inside the conveyor set to engage the idler ring gear. Now the energy is transmitted from the secondary counter shaft to the coupling through the planetary gear set. The planetary gear ser was conceived for the conveyor to be driven and make the planetary gears turn with the rear teeth engaged in the stopped ring gear. The front teeth of the planetary gears engage and drive the idler ring gear at reduced speed. Therefore, the coupling now engages the idler ring gear, drives the output shaft at a reduced speed to obtain the required reduced range.

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Transmission - Creeper

Creeper - Exploded view

RCPH10TTS018GAF

(1) (2) (3) (4) (5) (6) (7)

Roller bearings Thrust washer Needle bearings Spacer Cone bearings Output axle retainer Roller

(8) Allen screw (9) Shims (10) Exterior ring gear (11) Support plate (12) Intermediate ring gear (13) Planetary gears (14) Support

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(15) (16) (17) (18) (19) (20)

Coupling Output axle Needle bearings Thrust washer Selector yoke Shift rail

Transmission - Creeper

Creeper - Remove 1. Drain the oil from the transmission. 2. Separate the rear axle from the transmission. 3. Remove the gear shift cover. 4. Remove the snap ring, the thrust washer and that hydraulic pump idler gear located on the output shaft retainer (2). 5. Remove the retaining bolts (3) for the rear support plate (1) and lever the support plate away from the transmission.

RCPH09TTS167AAD

RCPH09TTS168AAD

RCPH09TTS169AAD

6. Remove the rear support plate (2) and PTO shaft (1) as an assembly.

7. Extract the secondary countershaft assembly (1) out enough to free the bearing from its location. 8. Lift up on the secondary countershaft and remove the output shaft and reduction gear set assembly (2).

9. Remove the secondary countershaft. 10. Remove the high/low/creep coupling from the rear of the transmission, or the output shaft, as needed. Next operation: Creeper - Disassemble (21.160)

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Transmission - Creeper

Creeper - Disassemble Prior operation: Creeper - Remove (21.160) 1. Remove the output shaft retainer (1) from the rear support plate (2). 2. Remove the outer ring gear (3) from the rear support plate.

RCPH09TTS170AAD

RCPH09TTS172AAD

RCPH09TTS171AAD

3. Remove the output shaft (2) from the reduction gear set assembly (1). Use a soft faced hammer to drive the output shaft forwards out of the assembly, if needed. Ensure the intermediate ring gear (3) remains inside the reduction gear set. NOTE: Removing the output shaft pushes the bearing off the rear of the output shaft.

4. Remove the thrust washer (3) and the needle roller bearing from the output shaft (or from the intermediate ring (4), if the components remained inside the gear set assembly). 5. Lay the planetary gear set on the workbench with the intermediate ring gear upward and remove the intermediate ring gear. 6. Remove the thrust washer, needle roller bearing, spacer and the second needle roller bearing from the carrier (1). 7. Remove the planetary gears (2) from the carrier. Take care to retain the bearing rollers. Next operation: Creeper - Inspect (21.160)

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Transmission - Creeper

Creeper - Inspect Prior operation: Creeper - Disassemble (21.160) 1. Inspect the output shaft retainer and rear bearing cup for damage or wear. Replace as required. â&#x20AC;˘ To remove the bearing cup from the retainer, use a puller tool and a slide hammer. â&#x20AC;˘ To install the bearing cup, use a step plate. 2. Inspect the support plate for damage or wear. Replace as required. 3. Inspect the output shaft and pilot bearing for damage or wear. Replace as required. 4. Inspect the secondary countershaft and the PTO drive shaft bearings located in the rear support plate. Replace any unserviceable bearing with a suitable step plate. 5. Inspect all needle roller bearings and thrust washers. Replace any unserviceable items. 6. Inspect the planetary gear set carrier, ring gears and planetary gears for damage or wear. Replace as needed during assembly. NOTE: If several components are damaged or worn, replace the complete reduction gear set assembly. 7. Inspect the coupling and gear shift mechanism. Replace any unserviceable components. Next operation: Creeper - Assemble (21.160)

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Transmission - Creeper

Creeper - Assemble 1. Install the planetary gears (1) and rollers (4) in the carrier (2). Rest the carrier inside the outer ring gear (3), which acts as an assembly gauge.

RCPH09TTS173AAD

RCPH09TTS175AAD

RCPH09TTS177AAD

RCPH09TTS176AAD

2. Turn each gear until the master tooth (marked with a pick stroke) points to the center of the support. If the master tooth is not marked, take these actions to identify the master tooth:

â&#x20AC;˘ 5.7:1 reduction - Use a rod (1) between the gears to establish which pair of teeth of the rear gear align with a pair on the front gear. Looking from the front, there are four pairs of aligned gears. Identify the right teeth of any aligned pair in the 12-tooth gears (2) as the master tooth (3).

â&#x20AC;˘ 10:1 reduction - Use a rod (1) between the gears to establish which pair of teeth of the rear gear align with a pair on the front gear. Looking from the front, there is only one pair of gears aligned. Identify the tooth opposite the pair that is aligned in the 13-teeth gear (2) as the master tooth (3).

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Transmission - Creeper

3. Place the thrust washer (2) with the smaller diameter, beveled side up, on the support hub. Mount the intermediate ring gear (1) on the support to engage with the planetary gears.

RCPH09TTS178AAD

RCPH09TTS179AAD

RCPH09TTS180AAD

4. Place the coupling, with the slot in front, in the output axle. 5. Place the washer (1) with the bigger diameter on the output axle (2), beveled side facing the coupling (3).

6. Lubricate the needle bearings with high quality grease and install the narrow needle bearings on the intermediate ring gear. Install the wider needle bearings, with a spacer in between, on the support. 7. Keep the previously mounted output axle in a vertical position and place the support on the output axle. NOTE: Once the support has been correctly mounted, the output axle must project over the side of the support. 8. Tighten the rear bearings of the output shaft against the back of the output shaft shoulder (1). 9. Use feeler gauges (2) to check separation between the bearings (3) and the support. The separation must be 0.03 - 0.08 mm (0.0012 - 0.0031 in).

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Transmission - Creeper

Creeper - Install Prior operation: Creeper - Assemble (21.160) 1. Install the mounted support and output axle in the transmission. Make sure that the coupling engages in the selector yoke. 2. Take out the external ring gear from the set of reduction gears. 3. Install the rear plate in the transmission. 4. Secure the rear plate with the screws. Torque the bolts toTorque the bolts to 47 N·m (35 lb ft). 5. Place the external ring gear on rear plate. 6. Mount the shims. Use the Allen screws to secure the retainer of the output axle to the support plate and ensure the ring gear is also secured. Tighten the Allen screws to a torque of 31 N·m (23 lb ft). 7. Measure the preload: • Use a dynamometer and a cord wound around the output axle, with the transmission in neutral. The dynamometer must record between 1.0 - 1.8 N (0.22 - 0.40 lb). If the result is not within specification, add or remove shims between the output axle retainer to achieve the correct preload. • If a dynamometer is not available, add or remove shims until the clearance in the output axle is between 0.03 - 0.086 mm (0.001 - 0.003 in). 8. Install the intermediate gear of the hydraulic pump and the thrust washer. Secure with a snap ring.

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Index Transmission - 21 Creeper - 160 Creeper - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Creeper - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Creeper - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Creeper - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Creeper - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Creeper - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Creeper - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Creeper - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Creeper - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Four-Wheel Drive (4WD) system - 23

[23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2

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CONSUMABLES INDEX Consumable LoctiteÂ® 569

Reference Gearbox - General specification

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PAGE 23.2 / 5

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Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

TECHNICAL DATA Electro-hydraulic control General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Front-Wheel Drive (FWD) clutch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - General specification Specifications Type: Installation centralized on rear axle with electro-hydraulic non-sliding clutch action of the tooth type. Electro-hydraulic mechanical engagement and disengagement. 0.930:1 and 0.907:1 Transfer box ratio 44 No. of intermediate gear teeth 40 and 39 No. of driven gear teeth Clearances and Adjustments Intermediate gear bearing turning force 0.45 - 1 kgf With adjustment by shims 0 mm, 10 mm, 0.25 mm, 0.30 mm, 0.50 mm Shims available for the intermediate gear Output shaft bearing turning force 1.9 - 4.5 kgf (With adjustment by shims) 0 mm, 10 mm, 0.25 mm, 0.30 mm, 0.50 mm Shims available for the output shaft bearings 48.0 mm Free length of clutch spring Oil, Capacity Transfer Box Assembly Lubricated by Oil from the Rear Axle Addition of the quantity of rear axle oil with the 1.3 l transfer box installed

Electro-hydraulic control - Torque Components Rear axle transfer case fixing screws Transmission shaft screws Idler gear fixing screws Oil drain plug End cover screws

Nm 66 N·m 57 N·m 80 N·m 80 N·m 51 N·m

Kgf/m 6.6 kgf 5.7 kgf 8.0 kgf 8.0 kgf 5.1 kgf

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Overview When the dual mobile lead-in valve placed in the central hole moves forward, the pressure oil passes through the valve center and lifts the internal ball from its seat and allows oil to reach the chamber. The camber is closed by two rings. Oil expands inside the chamber and moves the friction gear against the springs arranged in rays, thus removing the gear trigger teeth. Now the gear can turn freely on the front axle because it is disconnected. The solenoid stops working when cutting off the electrical circuit in feed tubes and in chamber. The spring pressure makes the clutch move towards the driven gear. Independent of which way the clutch moves, when discharging the oil the whole lead-in valve moves backwards. This way the first lead-in ball does not allow oil to pass through the valve center any longer, and the whole valve moves backwards. This movement causes a big open escape passage through the radial drill holes on axle and gear, towards the rear axle. A quick disconnection of the clutch is thus achieved. At first, a small quantity of oil comes out from the solenoid so that lead-in valve can move.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) clutch - Sectional view

RCPH10TTS008FAF

(1) Driven gear (2) Oil transfer tube (inside) (3) Lead-in valve (ball raised)

(4) Chamber (5) Return springs - 4 total (6) Spring retainer

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(7) Friction clutch (8) Oil outlet (9) Lead-in valve (seated ball moved backwards)

Index Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202 Electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electro-hydraulic control - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front-Wheel Drive (FWD) clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front-Wheel Drive (FWD) clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

TECHNICAL DATA Gearbox Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Gearbox Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Gearbox Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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CONSUMABLES INDEX Consumable LoctiteÂ® 569

Reference Gearbox - General specification

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PAGE 23.2 / 5

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Torque

RCPH10TTS006GAF

(1) (2) (3) (4)

51 N路m 40 N路m 50 N路m 80 N路m

(38 lb (30 lb (37 lb (59 lb

ft) ft) ft) ft)

Gearbox - General specification The gear box (transfer case) is located in the rear shaft, central mounting. The gear box has a trigger-type electrohydraulic actuator with anti-sliding clutch and with mechanical connection, electro-hydraulic disconnection.

Ratio Gear box Intermediate gear teeth Driven gear teeth

1.0232: 1, or 0.9767: 1 43 2, 43 or 44

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Free plays and adjustments Resistance to turning of intermediate differential bearing: 0.4 - 1.0 kgf (0.88 - 2.20 lbf) Adjustable by calipers: 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.3 mm (0.012 in), 0.5 mm (0.020 in) Resistance to turning of output shaft bearings: 1.5 - 3.5 kgf (3.31 - 7.72 lbf) Adjustable by calipers: 0.1 mm (0.004 in), 0.25 mm (0.010 in), 0.3 mm (0.012 in), 0.5 mm (0.020 in) Free length of clutch springs: 48.0 mm (1.890 in)

Lubrication Fluid type: Capacity: Increase in rear shaft, to the installation of rear shaft

Rear axle oil 1.3 l (2.7 US pt)

Thread sealant Setscrew, intermediate gear

LOCTITEÂŽ 569

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Overview All gear boxes are identical in their construction, with the only difference being their gear ratios. The different gears are required to adapt to the different front and rear tire sizes. The ratio appears in the front side of the case, under the output axle. The gear box includes a trigger type clutch to connect the drive to the front axle. This clutch trigger activates with the hydraulic pressure taken from the dual power and the independent power take-off circuits. A helicoidal gear installed on the drive pinion shaft transfers drive to an intermediate gear supported by two tapered bearings in the gear box and a third gear in the lower shaft. Refer to Gearbox - Sectional view (23.304). Gear ratios in the assembly are determined by the number of teeth of the output lower gear. The lower axle is supported by two tapered bearings and has a friction gear with a splined trigger in the center. The driven gear includes a match gear that, when not connected, allows the friction component to turn freely on the axle. The clutch connects through the tour springs arranged in rays and loosens by means of the hydraulic pressure sent by an electric switch in the instrument panel. An electro-valve sends hydraulic oil from the dual power and the independent take-off power circuits, through an external tube, to the rear plate of the gear box. When the solenoid starts working, oil passes through the transfer short tube to the lower axle central hole.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Sectional view

RCPH10TTS011GAF

(1) Friction clutch (2) Spiral springs - 4 total (3) Output shaft (4) Solenoid valve

(5) Electric input connection (6) Hydraulic oil connection (7) Lock rings (8) Oil external tube

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(9) Dual lead-in valve (10) Oil transfer tube (11) Driven gear (12) Intermediate gear

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Exploded view

RCPH10TTS012GAF

1. Bolt 2. Collett 3. Spacer 4. Idler gear 5. Back plate 6. Oil transfer pipe 7. O-ring seal 8. Bearing 9. Thrust Washer 10. Main Valve 11. Driven gear

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Output axle Detent rings Clutch Spring plate Retaining Ring Collett Front plate Felt lip detent O-ring seal Bearing Springs - 4 total

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23. 24. 25. 26. 27. 28. 29. 30. 31. 32.

Solenoid cover Solenoid/valve Casing Oil tube Retainer Collett Bearing Collett Bearing Axle

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Disassemble 1. Remove the drain plug (1) of rear axle/gear box and collect oil in a suitable container. 2. Remove the solenoid cover (2) on the right side of the gear box.

RCPH09TTS364AAD

RCPH09TTS365AAD

3. Disconnect the solenoid cable and the cable protection tube. 4. Disconnect the hydraulic input tube from the case. 5. Elevate the gear box with a jack and remove the setscrews. Lower the gear box and remove it from the machine.

(1) Spool entrance (2) Solenoid (3) Ground electrode (4) Feed cable (5) Electrical protection tube (6) Hydraulic input tube 6. Remove the oil end tube that connects the solenoid entrance to gear box cover. Remove the solenoid spool setscrew and remove the spool from body. Unscrew and remove the valve/body from the recess.

RCPH09TTS366AAD

(1) Valve/body (2) Ground cable (3) Fixing nut to ground (4) Spool and entrance cable

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

7. Loosen the Allen screw (1) that fixes the intermediate gear (2) and bearing. If necessary, carefully heat the nut (3) to loosen the factory-applied adhesive used to fix the thread.

RCPH09TTS367AAD

RCPH09TTS368AAD

RCPH09TTS369AAD

RCPH09TTS370AAD

8. Remove the central shaft (1) and mark the front part of intermediate gear (2) for easier mounting later. Remove the gear and bearing (3). Store the bearings, spacers and calipers together in for reassembly.

9. Remove the setscrews from detent support/plate (1) on the output shaft (2) and remove the plate and the o-ring (3). Collect and identify the calipers (4) placed between the plate and the bearing external track.

10. Remove the setscrews from the rear plate and remove the plate. Remove the short oil transfer tube from shaft, if still connected to shaft. 11. Carefully remove the shaft from the front and rear parts and remove the external tracks from the front and rear bearings.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

12. With the help of another operator, use the levers (1), which are detachable from the tires, and use the socket wrenches (5) to pry the plate (3) against the clutch springs (4) to release the load on the circlip (2). 13. Remove the circlip and the four clutch springs.

RCPH09TTS371AAD

RCPH09TTS372AAD

14. Place two support braces (5) between the driven gear (3) and front part of case. Apply pressure to the shaft (4) to remove the case through the driven gear. Remove the bearing (2).

15. Release the shaft forwards as much as clutch allows and remove the driven gear and the thrust washer. 16. With the shaft (1) still forwards, place the puller and a suitable attachment around front bearing (2) and remove the bearing.

RCPH09TTS373AAD

17. Remove the gear circlip by passing it over the flat part of shaft and over the short splines area.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

18. Move the shaft (3) backwards and the clutch (2) forwards in order to access the detent rear ring (1). Remove the ring.

RCPH09TTS374AAD

RCPH09TTS376AAD

RCPH09TTS375AAD

19. Move the shaft (3) backwards through the clutch (1) and the rear bearing hole. Remove the clutch and spring plate (2).

20. To remove the passage valve (2) from the shaft central hole (1), apply compressed air through the drill hole, between the clutch detent rings.

Next operation: Gearbox - Assemble (23.304)

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Assemble Prior operation: Gearbox - Disassemble (23.304) 1. Install new o-rings on both plates and install a new detent ring inside the small diameter of the shaft. NOTE: Do not install the main ring until the shaft is in the case. 2. Grease the lead-in passage valve with grease and fix the valve in the shaft. Ensure the valve is placed with the spring pointing to the rear ball, as shown.

RCPH09TTS378AAD

RCPH09TTS374AAD

RCPH09TTS380AAD

3. Pass the shaft (4) through the rear bearing hole and through the clutch (2) and the plate. 4. Install a new detent with a larger diameter on the clutch. Lubricate the front (3) and the rear (1) detent rings. 5. Install the clutch on the shaft, with the clutch closed.

6. With the shaft completely forwards, assemble the driven gear (2) and thrust washer. 7. With the correct spacer, place the rear bearing (1) inside the shaft while holding the front part. 8. Install the circlip in the shaft next to the plate in a straight line.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

9. Install all four clutch springs. 10. With the help of another operator, use the levers (1), which are detachable from the tires, and use the socket wrenches (5) to push the plate (3) against the clutch springs (4) to apply load on the circlip (2). Ensure the circlip is properly seated on tis groove.

RCPH09TTS371AAD

RCPH09TTS383AAD

RCPH09TTS369AAD

11. Pass the external track of the front bearing through and mount the front bearing retainer without its felt detent and calipers. 12. Tighten the screws and check the axial play by installing a dial comparator against the clutch and moving the shaft forwards and backwards.

13. Select shims that match the corresponding assembly and then add another 0.1 mm (0.004 in) shim to the result. 14. Remove the front bearing retainer and install the plate (2) and shim (1) assembly. Manually tighten the plate screws.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

15. Use a spring scale (1) and a piece of rope (2) to measure the turn resistance of the shaft inside their bearing.

RCPH09TTS385AAD

RCPH09TTS386AAD

RCPH09TTS387AAD

16. Gradually tighten the screws to their specified torque and compare resistance. 17. Adjust the value of the shims to achieve required resistance. 18. Once specified torque is obtained, and with the screws correctly tightened, remove the front bearing plate and mount a new felt detent. 19. Calculate the preload of the tapered roller bearings. A. Pass the external tracks through the intermediate gear (1) and mount the internal bearings with a spacer (3) and with a shim (4) of 0.3 mm (0.012 in) between each bearing. B. Place the assembly on the adjustment fitter tool (2) and tighten the screw for the tool to a torque of 68 NÂˇm (50 lb ft).

C. With the adjustment fitter tool mounting on a bench vise, coil a piece of rope around the gear, and use a steelyard to measure the turn resistance of the bearings. NOTE: Read the spring scale while the gear is turning. Reading should not be done when the gear has just begun to turn. D. To reduce resistance, increase the value of the shim placed between the gears. To increase resistance, reduce the value of the shim. E. Repeat the adjustments until the required resistance is obtained.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

F. Use a wide micrometer (2) and measure the distance between the bearing internal tracks (1).

RCPH09TTS388AAD

RCPH09TTS389AAD

G. With a caliper, measure the distance between the support pins of the intermediate gear. H. Take the bearing measurement away from the pins measurement and determine the caliper. Divide the measurement by two to distribute in both sides. See the example that follows. Example: Width between bearing tracks = 3.75 mm Width between transfer case pins = 3.95 mm 3.95 - 3.75 = 0.2 Two 0.1 mm shims are required. One on each side of the bearing. 20. Remove the intermediate gear from the bench vise and remove the assembly from the adjustment fitter tool. 21. Slightly lubricate and mount the intermediate gear, the bearing and the predetermined shims on the gear box.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Gearbox - Check Inspection and repairs 1. Remove the retainer ring from the covers at the shaft ends (1) and (2), Fig. 1 and the sealing ring that remains in the central area of the shaft. 2. Remove the filter seal (2) from the oulet cover (1), Fig. 2. At this point, do not fit the new seal.

LAIL11TS0219A0A

LAIL11TS0220A0A

LAIL11TS0221A0A

LAIL11TS0222A0A

3. Wash all the components with a suitable solvent, including the activation valve, transfer the oil tube and retention valve from the centre of the shaft and leave them to dry naturally. 4. Remove the transfer box hydraulic oil feed tube from the tractor, Figure 3, and clean the small network filter located inside the adaptor now visible.

5. Inspect the retaining rings (1) and (3) and the support seals (2) in the valve core, replacing them if necessary, Fig. 3. 6. Carefully inspect the intermediate gear bearings. Replace the two bearings when they are spoiled. Remove the outer caps (2), from the gears, Fig. 4.

7. Inspect the intermediate gear teeth (1) and the bottom gear for wear or other damage. Check for wear or damage. Also inspect the rear axle pinion gear.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

8. Inspect the toothed clutch ridges, both on the sliding clutch component side (1), and the gear side (2). If the clutch ridges show wear, or if they do not have sharp ridges, both parts have to be replaced, Figure 5. 9. Examine all the clutch springs to see if they are deformed or stretched. The free length of the spring should be 48 mm (1.890 in). 10. Inspect the clutch and shaft splines. Check whether clutch slips freely in the splines. 11. Inspect the bottom shaft bearing assemblies. Replace if necessary. 12. Inspect the output shaft splining to the transmission shaft to see if it is worn or there if is other damage.

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LAIL11TS0223A0A

Index Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304 Gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Gearbox - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Gearbox - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Gearbox - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Gearbox - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Gearbox - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Gearbox - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Front axle system

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Loctite® 515 Loctite® 515 NEW HOLLAND AMBRA GR 75 MD

Reference

PAGE

Powered front axle - Overview

25.1 / 11

Bevel gear set and differential carrier - Preload

25.2 / 14

Differential - Install Differential - Install Steering knuckle and king pin - Adjust

25.2 / 27 25.2 / 27 25.3 / 27

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Front axle system - 25 Powered front axle - 100

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Powered front axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Axle support Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Powered front axle Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Four-Wheel Drive (4WD) axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Powered front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Four-Wheel Drive (4WD) axle Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Axle support Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC TRANSMISSION OIL

Reference Powered front axle - Overview

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PAGE 25.1 / 11

Front axle system - Powered front axle

Powered front axle - General specification Specifications Type Pair of bevel gears - differential Pinion crown gear ratio Clearance Between the pair of bevel gears: Pinion bearing adjustment spacer thickness (7), and (4) Thickness of pinion bearing adjustment spacer (12) Thickness of shim and crown adjustment ( (4)

Gap between the satellite teeth and planetary (gear) Thickness of planetary shim Thickness of satellite shim Diameter of transverse pin 14 to satellites Diameter of transverse holes from satellite Clearance between transversal pins and holes Diameter of lateral planetary hubs Diameter of hole in differential box lateral planetary hub Clearance between satellites and holes

steering, load support structure, central articulation 10 / 32 = 3.2 : 1 0.15 to 0.20 2.5 - 3.7 mm at 0.1 intervals 2.5 - 4.8 mm at 0.05 intervals 0.9 mm - 1 mm - 1.1 mm - 1.2 mm - 1.3 mm - 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm 1.8 mm - 1.9 mm - 2 mm 0.15 mm 1.470 - 1.530 mm 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm 1.8 mm 21.939 - 21.960 mm 22.040 - 22.061 mm 0.080 - 0.122 mm 43.961 - 44.000 mm 44.080 - 44.119 mm 0.080 - 0.158 mm

Shaft and pivot housings Diameter of external shafts ( (5) and (7)) in relation to bushings (8) Internal diameter of the installed bushing (8) Clearance between the shafts and bushes. Interference between bushes and the respective holes Thickness of adjustment shim for pin (7)

41.975 - 42.000 mm 45.100 - 45.175 mm(1) 0.100 - 0.200 mm 0.064 - 0.129 mm 0.10 mm - 0.15 mm - 0.20 mm - 0.25 mm 0.30 mm

Final epicyclic transmission Gear ratio: Thickness of gear shim ( (1)

6:1 0.77 - 0.83 mm

Axle articulation End clearance between the shaft housing and bearings Maximum admissible clearance Articulated axle front pin diameter Inside diameter of installed front bushings Clearance between the pin and bush Rear bush external diameter installed in bevel pinion support Rear bush external diameter installed in bevel articulated axle support Clearance between the two bushes and pins Thickness of front and rear reinforcing shim for front shaft (1) Measurement to be obtained without dilation

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0.3 - 1.1 mm 2 mm 52.652 - 52.671 mm 52.720 - 52.790 mm(1) 0.049 - 0.138 mm 99.020 - 99.050 mm 99.146 - 99.221 mm(1) 0.096 - 0.201 mm 4.90 - 5.00 mm

Front axle system - Powered front axle

Powered front axle - Torque

BRAG11TRCNH0236

Powered front axle - Special tools Special tools NOTE: Tools marked with the symbol (X) are ESSENTIAL to the operations described in this manual. To ensure work is carried out efficiently and in a safe manner and to obtain the best results, the specific recommended tools and other tools produced in accordance with the designs in this manual must be used 297471 – Kit to disassemble the tractor 297617 – Stands to support the engine (with 297471) 380000844 – Adaptor boards for supporting the engine (with 297617)

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Front axle system - Powered front axle

List of specific tools required to carry out the various operations described in this Section. 293460 Stand for maintenance of the front bridge. 291517 Hanger to lift the differential support. 293743 Support for maintenance of the differential. 293889 Guide for installing the front bridge in the support housing. 293400 Universal gauge for positioning the conical pinion. 292888 Guide pins (M 12 x 1.25) for the epicyclic reduction gear cover. 293812 Guide pins (M 16 x 1.25) for installing the wheels. X 293878 Wrench for the conical pinion nut. X 293391 Model for adjusting the conical bearings and positioning the conical pinion. X 293782 Wrench for locking the conical pinion. X 293665 Wrench for the nut to adjust the differential bearing pre-load. X 293880 Wrench for the wheel hub nut. X 293857 Extractor for the articulated pin of the wheel hub articulated seal. X 292161 Extractor for the pin bushings of the rotor housing. X 292220 Adaptor for measuring the pre-load of the rotor housing. The tool should be made to adjust the conical pinion and used in conjunction with tool 293391. Made using UNI C40.

LAIL11TS0017A0A

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Front axle system - Powered front axle

Axle support - Torque Torque values

LAIL11TS0001A0A

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Front axle system - Powered front axle

Powered front axle - Dynamic description Description and operation The machine has a central front wheel drive and a coaxial drive shaft in the longitudinal direction of the tractor. The drive shaft has no universal joints. The differential has two planetaries and movement is transmitted to the lateral epicyclic final units (installed in the wheel hubs) through universal joints that do not require any maintenance.

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Front axle system - Powered front axle

Powered front axle - Overview 4 WHEEL DRIVE FRONT AXLE DESCRIPTION AND OPERATION “Carraro” type front axle is identified by means of a nameplate placed on the back of the right axle housing. The nameplate also has a series number and a reference number for gear ratios, oil capacity and type of grease. When ordering parts, always indicate type, reference and series number (see New Holland specifications for oil and grease). Axles pivot in the center to allow articulation when driving on uneven terrains, and the drive axle or drive pinion passes through the hollow center of the back of connecting point. This layout supports the drive axle by connecting the front axle to the transfer box on a straight plane in any type of articulation. Connection of drive axle is complemented by two universal gaskets and a sliding connection outlet. Final reduction is achieved through three epicyclic gears on a replacement hub fixed to the tube by means of upper and lower coupling links that revolve on cup and cone bearings and that can be lubricated and replaced to increase durability. Each type of axle has a central differential in the axle housing supported by replaceable supports. The differential of each type of axle has a controlled standard sliding system. The action of the sliding control is achieved by means of multidisc gears placed on each side of side differential gears. When one of the two front wheels looses traction, torque response on differential exerts an axial force through the side gears, pressurizing gear discs. External discs are fixed to differential casing and internal discs are fixed to side gears so, when force increases, it is difficult for friction surfaces to move independently. Thus, side gears remain fixed to casing causing a differential lock. As soon as the tendency to slide disappears, torque response decreases and the system unlocks automatically. Each axle has a removable drive cylinder fixed to the differential support. A double sided piston controls a rod that extends through each cylinder end. Some braces with ball joint connect drive cylinder to each hub. Except for the differential, the reduction hubs, hub bearings, wheel shafts and drive cylinders can be dismantled without having to remove machine’s shaft.

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Front axle system - Powered front axle

Powered front axle - Sectional view Front wheel drive cross â&#x20AC;&#x201D; section

LAIL11TS0018A0A

1. Tractor axle front support bearing 2. Front backing washer 3. Front articulated pin

4. Rear backing washer 5. Rear axle support bushing 6. Rear axle support bushing (seat)

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Front axle system - Powered front axle

Powered front axle - Overview Front Axle Cane harvester TS6000 tractors â&#x20AC;&#x201C; are being fitted with a reinforced front axle (P.N. 87602180) to replace the conventional front axle as illustrated in the figures below. According to Service Bulletin 037-2008, the lubricant oil changing period has been changed for the New Holland front axle final reducer from 1200 h to 300 h. The change interval can be less than 300 h depending on the tractor's working conditions Change the final reducer lubricant oil on NEW HOLLAND front axles every 300 h working hours following the operator manual recommendations. Use NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL lubricating oil or similar, with a specification of API GL-4 or higher.

LAIL11TS0253A0A

Top view of reinforced front axle

The lubricant oil level is obtained by placing the drain / filling plug forward in the 3 h position. This procedure is described in detail in the Operator Manual. Another method is to drain completely the final reducer and fill with the recommended oil level for each class of axle. Cane harvester TS6000 Tractor (Axle: CNH class II HD): 1.5 l to final reduction gear.

LAIL11TS0254A0A

Front view of reinforced front axle

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Front axle system - Powered front axle

Four-Wheel Drive (4WD) axle - Sectional view AFWD output assembly â&#x20AC;&#x201D; Cross section

LAIL11TS0497F0A

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

Spring guard Output shaft front bearing Locking ring Oil sealant Output axle Protection Covers Cover retaining lock ring Cover "O" sealant. Internal piston sealant Clutch half/gear Locking ring Actuation gear (from transmission output) Bearing lock washer Locking ring Bearing assembly.

17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31.

Shaft (transmission output) Output shaft rear bearing Oil pressure supply tube Transmission housing Plug (supply under pressure) Oil transfer tube Oil transfer tube polyamide sealant Pilot valve assembly Bearing lock ring Needle bearings Steel washers Transmission drain plug External piston shaft Sliding clutch half Connecting spring assembly

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Front axle system - Powered front axle

Powered front axle - Remove Complete front axle Disassembling - Installing DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

NOTE: The front axle assembly can be removed from the tractor before or after disassembly of the transmission shaft. The description below refers to disassembly of the front axle with the transmission shaft installed on the tractor. To remove the transmission shaft, refer to Four-Wheel Drive (4WD) axle - Disassemble (25.100) Depending on the work to be done on the axle, it could be a help to loosen certain fastened nuts before dismounting the axle from the tractor. For example: • The wheel hub bearing nut on the right and left hand sides • Pinion safety nut • Wheel axle end nuts. Proceed as follows: 1. Disconnect the negative battery cable (1).

LAIL11TS0002A0A

LAIL11TS0020A0A

2. Remove the bolts (1) and remove the front mudguard supports (2).

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Front axle system - Powered front axle

3. Fasten the nylon cables to the front ballast, dismount the lock pin, lift the ballast from the tractor and place it in a safe position.

LAIL11TS0019A0A

LAIL11TS0076A0A

LAIL11TS0021A0A

LAIL11TS0082A0A

4. Disconnect the feed and return tubes (1) from the steering cylinder.

5. Remove the bolts (1) and disassemble the transmission shaft protection (2).

6. Expand and slide the lock ring (1) and the sleeve (2) over the front drive shaft.

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Front axle system - Powered front axle

7. Remove the front wheel drive shaft and central support.

LAIL11TS0090A0A

LAIL11TS0106A0A

LAIL11TS0099A0A

8. Insert the shims (1) on one of the sides of the axle articulation to prevent the axle and the jack from oscillating (2) or lifting the tractor.

9. Lift the tractor and place a support (3) beneath the deposit.

NOTE: Handle all parts very carefully. Do not put hands or fingers between two parts. Always use the appropriate protective clothing, safety goggles, gloves and shoes. 10. Loosen retaining bolts and remove front wheels.

LAIL11TS0023A0A

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Front axle system - Powered front axle

11. Loosen the front and rear fastening bolts (1) of the front axle support.

LAIL11TS0024A0A

LAIL11TS0025A0A

12. Using a lifting hook and two nylon cables (one for each side) separate the front axle from the tractor. To do this, remove the bushes and other front axle supporting components, according to the sequence in Fig 12. (1) Front support column (2) Segment 'O' (3) Spacer (4) Seal (5) Rear support column

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Front axle system - Powered front axle

Powered front axle - Disassemble NOTE: To service the front shaft, it must be mounted on the bench.

LAIL11TS0026A0A

LAIL11TS0027A0A

LAIL11TS0028A0A

LAIL11TS0029A0A

1. Unfasten the cover (1) and drain the shaft box oil.

2. Unfasten the cover (1) at the left end of the epicyclic transmission box; repeat the same operation for the right hand box.

3. Disassemble the rear support (1) of the front shaft; disassemble the front support and remove the ring.

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Front axle system - Powered front axle

4. Unbolt both fastening bolts (1) from the wheel shafts.

LAIL11TS0030A0A

LAIL11TS0031A0A

LAIL11TS0033A0A

LAIL11TS0034A0A

Before removing the wheel shafts, make sure that the hubs do not turn on the articulations, leading to the shaft falling from the work bench. 5. During disassembly, also remove the pins from their holes in the pin shaft housing and remove the shaft from the wheels.

6. Remove the retention rings (2) from the articulated pins on the cylinder rod, unbolt the fastening bolts from the cylinder pin (1), remove the pins and separate the two cylinders. Remove the four pins, rings, spacers and the cylinders complete with tubes.

7. Remove the fastening bolts from the left end of the transmission box cover (1). Bolt the two studs 292888 (2) and using a sliding hammer bolted to the oil drain plug, remove the cover (1) from the box.

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Front axle system - Powered front axle

8. Dismount the external retention ring (1) that holds the transmission gears (2) and remove the gears.

LAIL11TS0035A0A

9. Dismount the internal retention ring (1) that holds the transmission gears ( (2), Fig. 10) NOTE: If necessary, it is possible to remove the hub and the shaft housing stud together, without the need for removing the safety stud from the wheel hub bearing.

LAIL11TS0036A0A

LAIL11TS0037A0A

LAIL11TS0038A0A

10. Disassemble the lock (1) of the wheel hub bearing safety nut (2). 11. Remove the safety nut from the wheel hub bearing using special tool 293880.

12. Remove wheel hub (1) with the ring gear (2).

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Front axle system - Powered front axle

13. Remove wheel hub (1) with the ring gear (2).

LAIL11TS0039A0A

LAIL11TS0040A0A

LAIL11TS0041A0A

LAIL11TS0042A0A

14. Remove the three fastening bolts (1) from the bottom pin of the pin shaft housing. Remove the bottom articulated pin and the corresponding adjusting shims. 15. Remove the four fastening bolts (1) from the mudguard support (2) and remove the support.

16. Remove the three fastening bolts from the top articulated pin. 17. Remove the top articulated pin (1) and loosen the pin shaft housing (2).

18. Remove the fastening bolt (2) of the shaft (1).

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Front axle system - Powered front axle

19. Remove the shaft from the box. 20. To dismount the right end of the transmission unit, repeat the steps as for the left end transmission unit.

LAIL11TS0044A0A

LAIL11TS0045A0A

LAIL11TS0046A0A

LAIL11TS0047A0A

21. Remove the two fastening bolts from the conic support of the transmission-differential to the shaft box. Tighten the two studs 292888. (1) Remove the remaining bolts and separate the differential support from the shaft housing. Connect a winch (2) to the support and remove the differential support (3) from the shaft housing.

22. Remove the bolt (2) and remove the protection from the retaining nut (3).

23. Remove the differential adjustment nut, using tool 293665. 24. Repeat operation No. 22 for the other side of the differential.

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Front axle system - Powered front axle

25. Remove the two fastening bolts (2) from the crown covers of the transmission box (1).

LAIL11TS0048A0A

LAIL11TS0049A0A

LAIL11TS0050A0A

LAIL11TS0051A0A

26. Remove the bearing (1) and cover (2) of the differential bearing. 27. Repeat the operation on the opposite side.

28. Remove the differential from the support.

29. Straighten up the lock tab on the safety nut (1) of the splined shaft.

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Front axle system - Powered front axle

30. To loosen the pinion nut, it is necessary to manufacture a tool that holds the pinion shaft. This tool can be made by welding an appropriate 20 mm nut to the coupling end of the transmission shaft 81873108. Tool for the pinion shaft manufactured locally 1. Coupler - Part No. 81873108 2. Nut 20 mm

LAIL11TS0052A0A

LAIL11TS0053A0A

LAIL11TS0055A0A

LAIL11TS0056A0A

31. Remove the nut using tool 293878 (1) while preventing the bevel pinion shaft from turning with the locally manufactured tool.

32. Remove the retention ball from the sleeve.

33. Remove the pinion shaft (1) from the rear part of the box and remove the spacer, adjustment shims and bearing.

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Front axle system - Powered front axle

34. Remove the dust seal, oil seal (1) and the rear bearing.

LAIL11TS0057A0A

LAIL11TS0058A0A

Front wheel drive differential Setting When the differential assembly needs to be repaired, it will be necessary to adjust the clearance between the teeth of the planetary gears and satellite gears. Proceed as follows: 1. Clean the differential components very well and carefully, and remove all the vestiges of oil that may prevent the correct measurement of clearance. 3. Fit in the two satellite gears complete with backing shims and fix the pin with the fastening bolt with some turns to keep the pin in place. 4. Place a calibrator gauge into the differential housing. 5. Move the planetary gear on the left side in order to establish perfect contact with the satellite, and then push against the differential housing, and take the clearance readout on the calibrator gauge (Gs). 6. Repeat the above operation to measure the clearance on the right hand side, in the other planetary gear (Gd). Thus the shim to be installed in the differential housing is determined by: Ss = Gs - 0.25 mm for the planetary gear on the left side. Ss = Gs - 0.25 mm for the planetary gear on the right side. 7. Install the shims as closely as possible to the calculated values, and with the use of the calibration gauge, follow the procedures described above, checking that the clearance of the planetaries on the right and left sides is approximately 0.25 mm.

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Powered front axle - Disassemble NOTE: To service the front shaft, it must be mounted on the bench.

LAIL11TS0026A0A

LAIL11TS0027A0A

LAIL11TS0028A0A

LAIL11TS0029A0A

1. Unfasten the cover (1) and drain the shaft box oil.

2. Unfasten the cover (1) at the left end of the epicyclic transmission box; repeat the same operation for the right hand box.

3. Disassemble the rear support (1) of the front shaft; disassemble the front support and remove the ring.

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4. Unbolt both fastening bolts (1) from the wheel shafts.

LAIL11TS0030A0A

LAIL11TS0031A0A

LAIL11TS0033A0A

LAIL11TS0034A0A

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8. Dismount the external retention ring (1) that holds the transmission gears (2) and remove the gears.

LAIL11TS0035A0A

LAIL11TS0036A0A

LAIL11TS0037A0A

LAIL11TS0038A0A

10. Disassemble the lock (1) of the wheel hub bearing safety nut (2). 11. Remove the safety nut from the wheel hub bearing using special tool 293880.

12. Remove wheel hub (1) with the ring gear (2).

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13. Remove wheel hub (1) with the ring gear (2).

LAIL11TS0039A0A

LAIL11TS0040A0A

LAIL11TS0041A0A

LAIL11TS0042A0A

16. Remove the three fastening bolts from the top articulated pin. 17. Remove the top articulated pin (1) and loosen the pin shaft housing (2).

18. Remove the fastening bolt (2) of the shaft (1).

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19. Remove the shaft from the box. 20. To dismount the right end of the transmission unit, repeat the steps as for the left end transmission unit.

LAIL11TS0044A0A

LAIL11TS0045A0A

LAIL11TS0046A0A

LAIL11TS0047A0A

22. Install tool 380000255 (1) in the vice on the workbench. Fasten the differential support to the tool and remove the lifting cable 23. Remove the bolt (2) and remove the protection from the retaining nut (3).

24. Remove the differential adjustment nut, using tool 293665.

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25. Repeat operation No. 23 for the other side of the differential.

LAIL11TS0048A0A

BRAG11TRCNH0163

Axles of hydraulic block 26. Remove the differential lock internal control line.

27. Remove the two bolts that hold the external dome of the differential block, and replace them with two bolts with a minimum length of 70 mm . Gradually, loosen the four remaining bolts of the external dome of the differential block so that this allows the spring to be extended gradually. NOTE: Two bolts have to be fixed with a minimum length of 70 mm , as the dome's normal bolts are not long enough to allow the spring to extend to its full free length. 28. Remove the last two 70 mm bolts. Remove the dome (1) , the helical spring (2) and the differential blocking piston.

BRAG11TRCNH0164

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29. Remove the fixation ring that holds the differential blocking piston, and remove the sliding sleeve together with the two shims.

BRAG11TRCNH0166

BRAG11TRCNH0167

LAIL11TS0049A0A

30. Very carefully remove the piston from the hub.

31. Remove the two fastening bolts from the crown covers of the transmission box 32. Remove the bearing (1) and cover (2) of the differential bearing.

33. Repeat the operation on the opposite side.

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34. Remove the differential from the support.

LAIL11TS0050A0A

LAIL11TS0051A0A

LAIL11TS0052A0A

LAIL11TS0053A0A

35. Straighten up the lock tab on the safety nut (1) of the splined shaft.

36. To loosen the pinion nut, it is necessary to manufacture a tool that holds the pinion shaft. This tool can be made by welding an appropriate 20 mm nut to the coupling end of the transmission shaft 81873108. Tool for the pinion shaft manufactured locally

37. Coupler - Part No. 81873108 38. Nut 20 mm 39. Remove the nut using tool 293878 (1) while preventing the bevel pinion shaft from turning with the locally manufactured tool.

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40. Remove the retention ball from the sleeve.

LAIL11TS0055A0A

LAIL11TS0056A0A

LAIL11TS0057A0A

LAIL11TS0058A0A

41. Remove the pinion shaft (1) from the rear part of the box and remove the spacer, adjustment shims and bearing.

42. Remove the dust seal, oil seal (1) and the rear bearing.

Front wheel drive differential Setting When the differential assembly needs to be repaired, the clearance between the teeth of the planetary gears and satellite gears will need to be adjusted. Proceed as follows:

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43. Clean the differential components very well and carefully, and remove all the vestiges of oil that may prevent the correct measurement of clearance. 44. Fit in the two satellite gears complete with backing shims and fix the pin with the fastening bolt with some turns to keep the pin in place. 45. Place a calibrator gauge into the differential housing. 46. Move the planetary gear on the left side in order to establish perfect contact with the satellite, and then push against the differential housing, and take the clearance readout on the calibrator gauge (Gs). 47. Repeat the above operation to measure the clearance on the right hand side, in the other planetary gear (Gd). 48. Thus the shim to be installed in the differential housing is determined by: Ss = Gs - 0.25 mm for the planetary gear on the left side. Ss = Gs - 0.25 mm for the planetary gear on the right side. 49. Install the shims as closely as possible to the calculated values, and with the use of the calibration gauge, follow the procedures described above, checking that the clearance of the planetaries on the right and left sides is approximately 0.25 mm.

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Powered front axle - Alignment Checking the alignment between the wheels and steering When moved in a straight line, the front tractor wheels must be parallel to the longitudinal axis of the tractor or, as an alternative, a slight convergence of the front wheels is allowed, up to a maximum value of 6 mm measured from the ends of the wheel rims. To verify the exact value of the adjustment for the convergence of the tractor with front wheel drive, proceed in the following way: 1. Calibrate the front tires to recommended pressure.

LAIL11TL0498A0A

LAIL11TL0082A0A

2. Position the steering wheel so that the front wheels are aligned with the tractor. 3. Check if the wheels are parallel with the longitudinal axis of the tractor. 4. Measure the distance (1) between the internal front ends of the wheels at the height of the centre of the wheel hubs. 5. Then turn the front wheels 180 ° and measure the distance between the internal ends of the wheel at the height at the centre of the wheel hubs again, (2)checking whether this new value is equal to or greater than the previous distance (1) of a maximum of 6 mm. Turning the wheels 180 ° is necessary to eliminate the influence of any wear to the wheels on the measurement. 6. If it is necessary to correct the wheel alignment, disassemble the nut (2) and remove the wheel shaft stub (1) out of its housing. Loosen the nut (3) and adjust on terminal (1) inwards or outwards in order to increase or decrease the distance ( (2), Fig. 1). Replace the terminal (9) in its housing and check the alignment again as described in items 4 and 5. After the alignment has been adjusted within the recommended limits, fasten nut (3) to a torque of 180 N·m (132.8 lb ft) and nut (2) to 100 N·m (73.8 lb ft). NOTE: The auto-lock nut (2) must be replaced every time it is removed or partially loosened.

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Four-Wheel Drive (4WD) axle - Disassemble 1. Remove setscrews from drive shaft guard and remove guard. 2. Remove the setscrews (2) that secure the drive shaft (3) to the flange (1).

RCPH09TTS328AAD

LAIL11TM1801A0A

LAIL11TL0044A0A

3. Remove the shaft: 1. Gradually loosen the adjustment bolts from the front support pillar.

2. Using a lifting hook and two nylon cables (one for each side) separate the front axle from the tractor. To do so, remove the bushings and other support components from the front axle. 3. 1. 2. 3. 4. 5. 6.

Front support column Segment â&#x20AC;&#x2122;Oâ&#x20AC;&#x2122; Spacer Seal Rear support column Seal

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Four-Wheel Drive (4WD) axle - Inspect CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Four-Wheel Drive (4WD) axle - Disassemble (25.100) 1. Inspect the front support bushing (1) and the rear support bushings (2) of the differential housing and shaft for damage or wear. 2. Remove the o-ring (3) from the bushing inside the rear support. Clean the bushing contact surfaces. 3. Place the front and rear supports against the front and rear brackets. Check wear and tear by turning supports from one side to the other. If wear is excessive, bushings shall be replaced in pairs. NOTE: If shaft could be moved forward and backwards before it was dismantled, the thrust sides of bushings are worn.

RCPH09TTS331AAD

RCPH09TTS332AAD

4. To remove the support bushings: A. Remove the setscrew and lubricator. B. Use a press to remove the rear support bushing. C. Cut the front support bushing to remove it. 5. Mount new bushings so that the oil holes are aligned with the support hole. Mount the special setscrew and the lubricator.

(1) O-ring (2) Bushings (3) Bushing pilot tool and nipple (4) Support pillar (5) Pilot tools

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Four-Wheel Drive (4WD) axle - Remove Disassemble the range gear group bearings 1. Remove the bearing from the range gear assembly with an appropriate universal extractor, Figure 1.

LAIL11TS0422A0A

LAIL11TS0425A0A

LAIL11TS0426A0A

2. Remove the shaft assembly (2) through the rear part of the transmission, Figure 2. 3. Remove the medium range gear and the synchroniser assembly (1) through the side of the transmission. NOTE: It may be necessary to push the AFWD gear slightly backwards after removing the external lock ring from the bearing.

4. Remove the range assembly (2), taking care not to damage the needle bearing (1), Figure 3.

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Axle support - Remove WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

Split the front axle from the front engine support 1. Drain the cooling system. 2. Disconnect the negative battery lead (1)

LAIL11TS0002A0A

LAIL11TS0019A0A

LAIL11TS0022A0A

3. Use an appropriate cable to connect a block and tackle to the front weights and remove them (if installed).

4. 8030 Model Loosen the clamps (1), remove the fixing bolts from the clamp (2) and remove the exhaust duct from the heat exchanger. Release the clamps (1) and (2), and remove the air intake tube from the heat exchanger.

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5. Loosen the clamp (1) and remove the air filter intake tube.

LAIL11TS0032A0A

LAIL11TS0043A0A

LAIL11TS0054A0A

LAIL11TS0064A0A

6. Loosen the clamp (1) and remove the air filter intake tube.

7. â&#x20AC;˘ Loosen the clamps (1) and disconnect the radiator coolant hoses. â&#x20AC;˘ Remove the radiator support (2).

8. Loosen the clamp (1) and disconnect the coolant hose.

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9. Remove the heat exchanger intake and return lines from their fasteners (1).

LAIL11TS0070A0A

LAIL11TS0076A0A

10. Disconnect the intake and return lines from the steering cylinder (1).

11. Remove the front wheel drive drive shaft protection shield. 12. Extend and slide the retaining ring (1) and sleeve (2) over the front wheel drive shaft.

LAIL11TS0082A0A

LAIL11TS0090A0A

13. Remove the front wheel drive shaft and central support.

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14. â&#x20AC;˘ Position the splitting kit (1) 297471 beneath the tractor. â&#x20AC;˘ Use the supports (2) in the splitting kit to support the engine on the splitting platform.

LAIL11TS0099A0A

LAIL11TS0106A0A

LAIL11TS0116A0A

15. Position wooden chocks (1) between the front axle and the front support. This prevents pivoting of the axle.

16. Use a splitting bar and suitable chains or cables to secure the front and the rear of the support assembly to a mobile hoist.

17. Remove the front support fixing bolts and split it from the engine. NOTE: Ensure the support is properly installed and that it will remain stable when it is split from the engine. A support that is not fit for purpose may cause instability of the assembly resulting in possible personal injury, should the support tilt either backwards or forwards.

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18. Support the assembly on bridges at both the front and the back.

LAIL11TS0122A0A

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Axle support - Install Installation of the front axle and front engine support NOTE: If a new front support is being used or the engine deposit has been removed or replaced during servicing, the thickness of the new shims to be installed must be recalculated (see Axle support - Clearance (25.100)).

LAIL11TS0126A0A

LAIL11TS0116A0A

LAIL11TS0001A0A

LAIL11TS0099A0A

1. Check that the shims (1) are placed in their previous positions. 2. Check that the wooden shims (1) are between the front axle and the front support. This prevents pivoting of the axle. 3. Use a splitting bar and suitable chains or cables to secure the front and the rear of the support assembly to a mobile hoist.

4. Align the front support with the engine and install the fixing bolts in the front support to the engine. Tighten to the specified torque value.

5. Remove the supports (2) and the kit for division (1).

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6. Install the front wheel drive shaft and central support.

LAIL11TS0090A0A

LAIL11TS0082A0A

LAIL11TS0076A0A

LAIL11TS0070A0A

7. Expand and slide the lock ring (1) and the sleeve (2) over the front drive shaft. 8. Install the front wheel drive drive shaft protection shield.

9. Connect the input and return tubes from the steering cylinder (1).

10. Fasten the heat exchanger input and return tubes in their clips.

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11. Reconnect the coolant hose and tighten the clamp (1). 12. Connect the coolant hoses to the radiator and tighten the clamps (1).

LAIL11TS0064A0A

13. Install the radiator support (2).

LAIL11TS0054A0A

LAIL11TS0043A0A

LAIL11TS0032A0A

14. Install the air filter intake tube and tighten the clamp (1).

15. Install the heat exchanger air intake tube (intercooler, present in model 8030). Tighten the clamps (1) and (2).

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16. Install the heat exchanger air outlet tube (intercooler, only in model 8030). Tighten the clamps (1) and install the clamp fixing bolts (2).

LAIL11TS0022A0A

LAIL11TS0019A0A

LAIL11TS0002A0A

17. Use an appropriate cable to connect a block and tackle to the front weights and install them (if installed).

18. Connect the negative wire to the battery (1). 19. Fill the cooling system (see: filling the cooling system in the cooling chapter in the engine section). 20. Fill the steering system and hydraulic system completely with the correct fluid or oil.

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Axle support - Clearance Front axle and front support shim thickness calculation 1. Install a yellow, 4.5 mm shim (1) P/N 82026240 in each engine assembly stud.

LAIL11TS0126A0A

LAIL11TS0001A0A

LAIL11TS0191A0A

2. Align the front support with the engine and install the four top fixing bolts. Tighten to the specified torque value.

3. Use a feeler gauge to measure the clearance between each shim and the front support.

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4. Add the dimension obtained with the feeler gauge to the 4.5 mm thickness of the shim installed and select the adequate shim(s) in the table below. Color Code Yellow Green Red Blue White Black Pink Light Blue Gold Bright Green Orange Blue/Gray

Shim Thickness 4.5 mm 4.8 mm 5.1 mm 5.4 mm 5.7 mm 6.0 mm 6.3 mm 6.6 mm 6.9 mm 7.2 mm 7.5 mm 7.8 mm

P/N 82026240 82026241 82026242 82026243 82026244 82026245 82026246 82026247 82026248 82026249 82026250 82026251

5. Split the front engine support and replace the 4.5 mm shims with the shims of the calculated thicknesses. 6. Reinstall the front support and tighten the fixing bolts to the specified torque values.

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Index Front axle system - 25 Powered front axle - 100 Axle support - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 Axle support - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Axle support - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Axle support - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Four-Wheel Drive (4WD) axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Four-Wheel Drive (4WD) axle - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Four-Wheel Drive (4WD) axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Four-Wheel Drive (4WD) axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Powered front axle - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Powered front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Powered front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Powered front axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Powered front axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Powered front axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Powered front axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Front axle system - 25 Front bevel gear set and differential - 102

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Bevel gear set and differential carrier Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Differential Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Bevel gear set and differential carrier Bevel gear set and differential carrier - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Differential Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Preload - Side bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Loctite® 515 Loctite® 515

Reference

PAGE

Bevel gear set and differential carrier - Preload

25.2 / 14

Differential - Install Differential - Install

25.2 / 27 25.2 / 27

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Front axle system - Front bevel gear set and differential

Differential - General specification Front convergence Resistance to turning of shaft hub bearing Shaft wheel free play Reciprocating bearing preload

0 - 6.0 mm (0.00 - 0.24 in) Not adjustable, preadjusted Not adjustable, preadjusted 0.2 - 0.4 mm (0.008 - 0.016 in), for calipers: 0.10 mm (0.004 in), 0.19 mm (0.007 in), 0.35 mm (0.014 in) 9.3 - 13.9 kgf (20.50 - 30.64 lbf) 0.17 - 0.24 mm (0.007 - 0.009 in) Adjustable by calipers of :

Drive pinion rolling torque Backlash between ring and pinion Ring and pinion adjustment

â&#x20AC;˘ 2.5 - 3.4 mm, in units of 0.1 mm Differential bearing rolling torque Limits of clutch discs wear/Differential limited slip: Side disc (internal spline) New Minimum shim Side disc (internal spline) New Minimum shim

â&#x20AC;˘ 0.100 - 0.136 in, in unites of 0.004 in 3.8 - 4.8 kgf (8.38 - 10.58 lbf)

2.8 mm (0.110 in) 2.7 mm (0.106 in) 1.6 mm (0.063 in) 1.45 mm (0.057 in)

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Front axle system - Front bevel gear set and differential

Bevel gear set and differential carrier - Exploded view Transmission pinion components

LAIL11TS0002F0A

1. 2. 3. 4. 5.

Shim (Pinion depth) Bearing Bearing ring Housing Nut

6. Anti-dust cover 7. Seal 8. Ball 9. Sleeve 10. Bearing

11. Bearing ring 12. Shim (Pinion bearing pre-load) 13. Shim (Pinion bearing pre-load)

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14. Spacer 15. Segment 'O' 16. Pinion

Front axle system - Front bevel gear set and differential

Differential - Exploded view

RCPH10TTS010GAF

(1) Differential house (2) Shaft lockpin (3) Screw (4) Lock plate (5) Tightening nut (6) Bearing (7) Drive disc (external flange) (8) Friction disc (internal flange) (9) Thick pressure disc (10) Side gear

(11) Thrust washer (12) Differential gear (13) Shaft (14) Bevel gear (15) Pinion (16) Shim (17) Bearing (18) Washer (19) Spacer (20) Washer

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(21) Bearing (22) Lock washer (23) Ring nut (24) Flange (25) Shaft seal (26) Circlip (27) Flange, pinion shaft (28) Circlip

Front axle system - Front bevel gear set and differential

Differential - Sectional view Hydraulic Differential Lock

LAIL11TS0509G0A

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

Differential lock return spring Differential lock hydraulic feed Shim for adjusting clearance between crown and pinion teeth Pinion oil seal Pinion Nut Pinion Pinion bearing pre-load shims

8. 9. 10. 11. 12. 13.

Pinion depth shim Nut for adjusting differential bearing pre-load Nut safety lock for adjusting the differential bearing pre-load Crown Toothed gears Piston seals

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Front axle system - Front bevel gear set and differential

Differential lock Dog clutch - Dynamic description Hydraulic Differential Lock Operation

LAIL11TS0690G0A

On TS tractors with hydraulic differential lock (optional), drive is processed through a solenoid valve which, when energised, sends oil to the low pressure system ( 16 - 18 bar) to the lock piston, to engage the toothed gear. When power to the solenoid is cut, the return spring empties the oil from the piston and disengages the toothed gear, thus turning off the differential block.

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Front axle system - Front bevel gear set and differential

Differential lock Dog clutch - Dynamic description Description and operation - Self-locking system S30 Line tractors have a central front wheel drive and a coaxial drive shaft in the longitudinal direction of the tractor. The drive shaft has no universal joints. The differential has two planetary gears and movement is transmitted to the lateral epicyclic final units (installed in the wheel hubs) through universal joints that do not require any maintenance. The self-blocking system with friction gears, installed in the planetary gears is incorporated into the differential. This system constantly transmits the movement to both axles (right and left) but, under operating conditions, when there is a difference in wheel speeds, the system allows the friction plates (installed in the planetary gears), to slide, making the planetary gears (solidary to the axle) turn on the satellite, compensating the different speed existent between one axle and the other, without damaging the other components.

Differential adjustments with hydraulic lock Differential bearing adjustments and checking clearance between the pinion and crown. Proceed as follows: Install the differential mounted in the housing.

LAIL11TS0388A0A

LAIL11TS0389A0A

â&#x20AC;˘ Install the roller bearing covers in the housing case, adjust the differential cover support, fasten the bolts with torques corresponding to 59 NÂˇm (44 lb ft) and then loosen and fasten again with a torque of 20 NÂˇm (15 lb ft).

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Front axle system - Front bevel gear set and differential

• Install a shim (2) to adjust the clearance between the pinion/crown teeth of random measurement and lock ring (3). 1. Differential assembly 2. Shim (Clearance) 3. Locking ring 4. Toothed Gear 5. Lock segment

LAIL11TS0390A0A

LAIL11TS0391A0A

LAIL11TS0392A0A

• With the bearings perfectly lubricated, turn the differential and at the same time fasten the adjustment nut using wrench 293665 (1) to a torque of 39 - 59 N·m (29 - 44 lb ft) to maintain the axial gap between the components.

• Measure the gap between the pinion and crown using a 1/100 meter perpendicular to the external ridges of a crown tooth ( (1), Fig. 5).

• If the measured gap is not within the recommended tolerances, replace the shim ( (2), Fig. 3) to obtain the recommended value. NOTE: To obtain a greater clearance between teeth, use a thicker shim. To obtain a smaller clearance between teeth, use a thinner shim.

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Front axle system - Front bevel gear set and differential

• After adjusting the gap between the pinion and crown teeth, check the differential turning resistance, measured at the end of the pinion, with pinion lock key (2) 293782 and with torque meter (1) 293952 . The pinion + differential turning torque is 1.0 - 1.3 N·m.

LAIL11TS0393A0A

LAIL11TS0394A0A

LAIL11TS0395A0A

LAIL11TS0396A0A

• Should no torque meter be available, use a dynamometric balance. The turning force should be applied to a string wound around the pinion, in the grooved area. Pinion + differential turning force: 63 - 82 N (14 - 18 lb) If the recommended value is not obtained, adjust the differential adjustment nut ( (1), Fig. 7), fastening the nut to obtain the higher turning force. The maximum fastening torque of the adjustment nut is 6 kgf.

• Fasten the bearing bolts (Fig. 8 ) with a torque of 113 N·m (83 lb ft).

• After cleaning the blocking system components, carefully install the 2 new sealing rings on the block drive piston (4). 1. Toothed gear 2. Shim 3. Return Spring 4. Piston with O-rings (2x) 5. Hub 6. Lock segment 7. Retaining Ring

Install the block set in the differential, following the numerical order (Figure 9). Using the two 70 mm long bolts used in disassembly, it is possible to compress the spring (3) and install the original bolts in the hub (5).

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Front axle system - Front bevel gear set and differential

â&#x20AC;˘ Remove the 70 mm assembly bolts and install the original bolts. Install the safety lock (3), fastening the adjusting nut inwards or outwards, up to the closest tooth.

LAIL11TS0397A0A

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Front axle system - Front bevel gear set and differential

Bevel gear set and differential carrier - Preload Pinion shaft pre-load NOTE: Handle all parts very carefully. Do not put hands or fingers between two parts. Always wear the recommended safety clothing, including protective goggles, gloves and boots. Proceed as follows:

LAIL11TS0071A0A

LAIL11TS0072A0A

LAIL11TS0073A0A

1. Fix the tool 380000248 (1) in the clamp, install the internal races in the bearings (2) and (4) in the spacer (3) and fasten the tool nut until the end of run.

2. Use a micrometer to measure the (H1) distance between the top surface and the pin of tool 380000248 (1). 3. Disassemble the above parts, lubricate the bearings with transmission oil and then reinstall the parts, with the exception of the differential shaft housing bearing spacer (Fig. 1). Complete with the external races of the bearings, kept in place with tool 380000255 . 4. Tighten the nut on tool 380000248 (1) to the end, turning the tool to ensure that the bearings are correctly seated. 5. Use a micrometer to measure the distance (H2) with the tool in this condition. 6. The thickness required for the adjustment shim (4, page 5) is determined by: S = (H2 - H1) + 0.05 mm EXAMPLE: H2 = 10.5 mm H1 = 8.3 mm S = (10.5 - 8.3) + 0.05 mm S = (2.2) + 0.05 mm S = 2.25 mm 73403953 04/04/2014

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Front axle system - Front bevel gear set and differential

7. Remove tools 380000248 and 380000249 from the bevel pin housing. 8. Install the complete bevel pinion with internal bearing race, spacer and adjustment shim with the previously determined thicknesses. 9. Fit the O-ring sealing onto the pinion shaft. 10. Next, insert the retainer race and then the ball, after having carefully lubricated the external surface. 11. Install the key in the pinion lock 380000257 .

LAIL11TL0054A0A

LAIL11TS0393A0A

12. Install key 380000257 in the pinion nut. 13. Using a key, lock the pinion, and using a torque meter positioned on nut exactly as shown in , fasten the nut to a torque of 294 N·m (216.8 lb ft), and simultaneously turn the pinion to ensure that the bearings are correctly seated 14. Using a torque wrench (1) and a pinion lock 380000257 (2), check the pinion turning torque. If the turning torque is lower than the recommended value, install a thinner adjustment shim; if the torque value is higher, install a thicker adjustment shim.

NOTE: The pinion turning force measured with a balance must be 3,17 kgf . The values described are obtained with a low load torque meter, installed on the pinion shaft, with the bearings previously lubricated with NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL transmission oil. Pinion turning torque = 0.5 N·m (0.4 lb ft) Pinion + torque of differential turn = 1 - 1.3 N·m (0.7 - 1.0 lb ft) If it is not possible to use a torque meter, use a dynamometric balance and check the values below. The turning force should be applied to a string wound around the pinion, in the grooved area. Pinion turning torque = 31.7 N (7.1 lb) 73403953 04/04/2014

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Front axle system - Front bevel gear set and differential

Pinion + torque of differential turn = 63 - 82 N (14.2 18.4 lb) 15. After reaching the specified value, loosen the pressure nut and install the corresponding retainer and dustproof seal ring. Fasten the nut to a torque of 294 NÂˇm (216.8 lb ft) and simultaneously turn the pinion to ensure the bearings are correctly seated.

LAIL11TS0051A0A

16. Finally, carefully thread the nut (1) and install the lock ring.

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Front axle system - Front bevel gear set and differential

Bevel gear set and differential carrier - Clearance Pinion depth Proceed as follows:

LAIL11TS0060A0A

LAIL11TS0061A0A

LAIL11TS0062A0A

1. For the following steps, use tool kit 380000249. 2. Install the pinion bearings in the differential support housing and fasten them in position with tool no. NEW HOLLAND. 380000248 1.

Pinion measuring manometer

Pinion bearing clamp

Pinion bearings.

Micrometer.

If new tool NEW HOLLAND 380000248, as described in the procedure for adjusting the pinion bearing shims is not available, use the bearing fastening tool 380000249 to hold the bearings in place. 3. Install the roller bearings and tighten the fastening nuts to a torque of 113 NÂˇm. Install tool 380000249 (1) in the differential housing. 4. Adjust the cones of tool 380000249 so that the tip of the micrometer (4) touches the internal track of the pinion bearing and measure the size (H3).

5. Determine the corrected distance (H5) between the centre of the differential and the support base of the bearing in the pinion: H5 = H4 + C In that: H4 =bolt. 115 mm Nominal distance between the centre of the differential and the pinion bearing support base. C = the value of the correction inscribed on the pinion, preceded by the + or â&#x20AC;&#x201C; sign (if it differs from 0), to be added or subtracted from the nominal distance (H4), according to the sign (Fig. 4minimum).

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Front axle system - Front bevel gear set and differential

6. The shim thickness will be determined by: S = H3 - H5 In that: H3 = distance measured with the micrometer; H5 = corrected rated distance between the centre of the differential and the support base of the bearing in the pinion. EXAMPLE: – Distance measured with the micrometer H5 = 118 mm. - Rated distance between the centre of the differential and the support base of the bearing in the pinion: H4 = 115 mm. Value of correction C = + 0.2 mm. – Rated distance H5 corrected = 115 + 0.2 = 115.2 mm. - Shim thickness S = 118 – 115.2 = 2.8 mm.

LAIL11TS0063A0A

LAIL11TS0065A0A

Adjustment of pinion shim with tool VL Churchill FT.3135 1. Install the roller bearings (without the bearing cap) and tighten with a torque of 11.3 kgf/m. 2. Measure the internal dimension of the bearing diameter and call this dimension "A". 3. Install the pinion bearings in the differential support housing and fasten them in position with tool no. FT 3135. NOTE: Fasten the clamp so that the bearing cones can be turned by hand. 4. Place the bar manometer, tool part no. FT3135, until the bearing diameter and measure dimension 'B'. 5. Calculate dimension 'H4' using the formula. H4 = B -25* + (A/2) NOTE: *The bar manometer FT 3135 is 25 mm in diameter 6. Determine the thickness of shims S2 that will be installed behind the pinion gear as follows: S2 = H4 - H3 In that: H4 = Dimension calculated in step 5 above H3 = 115 mm + correction factor (C) 115 mm is the nominal dimension of manufacture of the rear face of the pinion gear to the conical tip of the pinion. (Supplied by the manufacturer.) C = Correction factor of manufacture, engraved on the pinion face.

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Front axle system - Front bevel gear set and differential

LAIL11TS0066A0A

1. 2. 3. 4. 5.

Depth manometer. Bar manometer - Tool part no. FT.3135 Pinion shaft bearings Pinion adjustment manometer - Tool no. FT3135 Differential; support box.

Example A= B= H4 = H4 = H4 = C= H3 = = Shim thickness S2 = =

95 mm 95.7 mm B -25* + (A/2) 95.77 -25* + (95/2) 118.27 0.1 mm 15 + 0.1 115.1

118.27 - 115.1 3.17 mm

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LAIL11TS0067A0A

LAIL11TS0068A0A

Front axle system - Front bevel gear set and differential

Installation of the shim and pinion bearing 7. Install the shim selected in the pinion shim adjustment procedure between the pinion head and bearing. Make sure that the chamfer on the shim is turned facing the pinion head. 8. Install the bearing in the pinion. NOTE: The use of an electronic induction heater will help to install the bearings without the use of a press.

LAIL11TS0069A0A

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Front axle system - Front bevel gear set and differential

Differential - Inspect Prior operation: Differential - Disassemble (25.102) 1. Inspect the differential side bearings. If necessary, remove the internal tracks with a puller and a suitable attachment.

RCPH09TTS345AAD

RCPH09TTS346AAD

RCPH09TTS347AAD

2. Inspect the pinion bearings. If necessary, remove the bearing internal track with a puller and a suitable attachment. NOTE: A shim is between the pinion internal bearing and its head. 3. Remove the external tracks from the differential housing support.

4. Inspect the differential gears, thrust washers and shaft for damage or wear. Replace as required. 5. Inspect the side gears and their splines for damage. 6. Inspect the bushings inside the differential housing for wear. If necessary, remove these bushings with a slide hammer and install new bushings.

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Front axle system - Front bevel gear set and differential

7. Inspect the limited slip clutch groups. Make sure the discs are perfectly flat. Inspect the area of the internal splines and external pins of the intermediate drive discs. Check that the internal discs are not worn more than 0.15 mm (0.006 in). New discs measure 1.6 mm (0.063 in). Compare worn discs with new ones. The thrust washer placed under the head of each side gear shall not be worn more than 0.1 mm (0.004 in). Washers have an original thickness of 2.8 mm (0.11 in).

RCPH09TTS348AAD

Next operation: Differential - Assemble (25.102)

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Front axle system - Front bevel gear set and differential

Differential - Assemble Assembling the pinion shim with the VL Churchill tool FT.3135 1. Install the roller bearings (without the bearing cover) and fasten with a torque of 113 N·m (83.3 lb ft). 2. Measure the internal dimension of the bearing diameter and call this dimension “A”. 3. Install the pinion bearings in the differential support housing and fasten them in position with tool No. FT 3135. NOTE: Fasten the clamp so that the bearing cones can be turned by hand.

LAIL11TL0063A0A

LAIL11TL0064A0A

LAIL11TL0065A0A

4. Place the template bar, tool part No. FT3135, through the bearing diameter and measure dimension “B”. 1.

Depth Micrometer

Template bar, tool part No. FT.3135

Pinion shaft bearings

Tool # 3135

Differential; support box

5. Calculate dimension “H4” using the formula H4 = B-25*+(A/2) NOTE: *The template bar FT 3135 has a diameter of 25 mm 6. Determine the thickness of shims “S2” which will be installed behind the pinion gear as follows: S2 = H4 - H3 Where :H4 = Dimension calculated in step 5 above H3 = 115 mm + correction factor (C) 115 mm is the manufacturer's nominal dimension of the rear face of the pinion gear to the conical tip of the pinion. (Supplied by the manufacturer). C = Manufacturer's correction factor, engraved on the pinion face. Example A = 95 mm B = 95.77 mm H4 = B-25*+(A/2) H4 = 95.77–25*+(95/2) H4 = 118.27 C = 0.1 mm H3 = 15+0.1=115.1 Thickness of shim S2 = 118.27–115.1= 3.17 mm

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Front axle system - Front bevel gear set and differential

Installation of the shim and pinion bearing 7. Install the shim selected in the adjustment procedure of the pinion shim between the pinion head and bearing. Make sure that the chamber on the shim is turned facing the pinion head.

LAIL11TL0066A0A

LAIL11TL0067A0A

8. Install the bearing onto the pinion. NOTE: The use of an induction heater will help install the bearings without the use of a press.

Assembling bevel pinion Assembly of pinion internal bearing NOTE: Handle all parts very carefully. Do not put hands or fingers between two parts. Always wear the recommended safety clothing, including protective goggles, gloves and boots. Proceed as follows: 9. Fix the tool 380000248 (1) in the vice, install the internal races of the bearings (2) and (4) the spacer (3) and fasten the tool nut until the end of run.

LAIL11TS0071A0A

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Front axle system - Front bevel gear set and differential

10. Use a micrometer to measure the distance "H1" between the top surface and the pin of tool 293391 380000248 (1).

LAIL11TS0072A0A

LAIL11TS0073A0A

11. Disassemble the above parts, lubricate the bearings with transmission oil and then reinstall the parts, excluding the bearing spacer ( (3), Fig. 1), of the differential shaft housing, complete with the external races of the bearings, and kept in place with the aid of tool 293743. 12. Tighten the nut of tool 380000248 (1) to the end, while turning the tool to ensure that the bearings are correctly seated.

13. Use a micrometer to measure distance "H2" considering the tool in this condition. 14. The required thickness for the adjustment shim ( (4), Differential - Sectional view (25.102)) is determined by: 15. Remove tools 380000248 and 293400 from the bevel pinion housing. 16. Install the complete bevel pinion with internal bearing race, spacer, and adjustment shim with the previously determined thicknesses. S = (H2 - H1) + 0.05 mm Example:: H2 = 10.5 mm H1 = 8.3 mm S = ( 10.5 mm - 8.3 mm) + 0.05 mm S = ( 2.2 mm) + 0.05 mm S = 2.25 mm

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Front axle system - Front bevel gear set and differential

17. Fit the O-ring sealing (1) onto the pinion shaft.

LAIL11TL0071A0A

18. Next, insert the retainer race and afterwards the ball, after having carefully lubricated the external surface. 19. Install the pinion lock key 380000257 (2).

LAIL11TL0072A0A

LAIL11TL0073A0A

20. Install key 380000268 (1) in the pinion nut. 21. Using a key, lock the pinion (2), and using a torque meter positioned on the nut (1) exactly as shown in figure 3 , fasten the nut to a torque of 294 NÂˇm ( 217 lb ft), and simultaneously turn the pinion to ensure that the bearings are correctly seated 22. Using torque wrench TORQUE WRENCH (1) and pinion lock 380000257 (2), check the pinion turning torque. If the turning torque is lower than the recommended value, install a thinner adjustment shim; if the torque value is higher, install a thicker adjustment shim in order to adjust it. NOTE: The pinion turning force measured with a balance must be 2,17 kgf, for both CNH class I HD and CNH class II axles

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Front axle system - Front bevel gear set and differential

Differential - Preload - Side bearing Prior operation: Differential - Assemble (25.102) 1. Locate measurement for the strength necessary to make the pinion shaft turn over bearings. This measurement was recorded during the previous operation. 2. With the crown in contact with the pinion and having adjusted the free play, turn the pinion with the rope and the spring scale. Record the strength needed to make pinion, crown and differential turn. 3. Subtract the turning resistance for just the pinion from the new value for the pinion and crown. For example: Pinion and crown: 12.2 kgf (26.90 lbf) Pinion only: 9.2 kgf (20.28 lbf) New value: 3.1 kgf (6.83 lbf) 4. Equally tighten each tightening nut of the differential side bearing until the turning resistance obtained is within the lower band of the specification. 5. Tighten the cover screws to specification.

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Front axle system - Front bevel gear set and differential

Differential - Install 1. Install the shaft housing assembly, after having carefully cleaned it and removed the oil from all the contact surfaces and applied a coat of LOCTITEÂŽ 515 of approximately: 2 mm thickness on the line shown in the figure below. Diagram for LOCTITEÂŽ 515 application for installing the differential and complete epicyclic unit.

LAIL11TS0001B0A

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Front axle system - Front bevel gear set and differential

Differential - Preload Differential adjustments Differential bearing adjustments and checking clearance between the pinion and crown. Proceed the following way: 1. Install the differential mounted in the housing.

LAIL11TS0050A0A

LAIL11TS0048A0A

LAIL11TS0078A0A

LAIL11TS0079A0A

2. Install the roller bearing covers in the as capas dos mancais dos rolamentos no housing case, adjust differential cover support, fasten the bolts with torques corresponding to 59 N·m ( 6 kgf/m) and next, loosen and fasten again with a torque of 20 N·m ( 2 kgf/m). 3. With the bearings perfectly lubricated, turn the differential and at the same time, fasten the adjustment nut using wrench 293665 (1) with a torque of 39 – 59 N·m ( 4 – 6 kgf/m) to maintain axial play among the components.

4. Measure the clearance between the pinion and crown using a 1/100 meter perpendiculr to the external ridges of a crown tooth (1, Fig. 4. 5. Repeat the measurement in other different position and compare the mean of the three values (Gm) with the recommended normal clearance.

0.15 - 0.20 mm, mean value of 0.18 mm 6. When the measured clearance is not within the recommended tolerance limits, adjust the nut in the following manner: Fasten one of the nuts inwards and the other outwards to the same value, to correct the axial pre-load and thus obtain the recommended clearance.

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Front axle system - Front bevel gear set and differential

7. After adjusting the clearance between the pinion and crown teeth, check the differential resistance to turning, measured at the end of the pinion, with pinion lock key (2) 293782 and with a torque meter (1) 293952. The pinion + differential turning torque is 1.0 - 1.3 NÂˇm.

LAIL11TS0077A0A

LAIL11TS0078A0A

LAIL11TS0048A0A

LAIL11TS0080A0A

8. Should no torque meter be available, use a dynamomeric balance. The turning force should be applied to a string wound around the pinion, in the grooved area. Pinion + differential turning force: 63 - 82 N ( 6.3 - 8.2 kg)

9. If the recommended value is not obtained, adjust the differential adjustment nuts (Fig 6), fastening the nuts equally to obtain the higher turning force. Maximum fastening torque of the adjustment nuts is 6 kgf. NOTE: Fastening must be applied equally on the right and left hand nuts, so as not to alter the clearance between the pinion and crown teeth. 10. Fasten the bearing bolts (Fig 7) with a torque of 113 NÂˇm ( 11.5 kgf/m).

11. Install the safety lock (3), fastening the adjusting nut inward or outward, up to the closest tooth.

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Front axle system - Front bevel gear set and differential

Differential - Disassemble Front axle - disassembly 1. To dismount the right end of the transmission unit, repeat the steps as for the left end transmission unit. 2. Remove the two fixation bolts from the conic support of the transmission-differential to the shaft box. Bolt the two studs 380000548 (1). Remove the remaining bolts and separate the differential support from the axle housing. Connect a winch (2) to the support and remove the differential support (3) from the axle housing.

LAIL11TL0041A0A

LAIL11TL0042A0A

LAIL11TL0048A0A

3. Install tool 380000255 (1) in the vice on the workbench. Fasten the differential support to the tool and remove the lifting cable. 4. Remove the bolt (2) and remove the protection from the retaining nut (3).

5. Remove the differential adjustment nut, using tool (1) 380000252. 6. Repeat operation numbers 3 and 4 for the opposite side of the tractor.

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Front axle system - Front bevel gear set and differential

7. Remove the two fixing bolts (2) from the crown covers of the transmission box (1).

LAIL11TL0049A0A

LAIL11TL0050A0A

LAIL11TL0051A0A

LAIL11TL0052A0A

8. Remove the bearing (1) and cover (2) of the differential bearing. 9. Repeat the operation on the opposite side.

10. Remove the differential from the support.

11. Straighten up the lock tab on the safety nut (1) of the splined shaft.

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Front axle system - Front bevel gear set and differential

12. To loosen the pinion nut, it is necessary to use a tool 380000257 that holds the pinion shaft.

LAIL11TL0053A0A

LAIL11TL0054A0A

13. Remove the nut using tool 380000268 (1) while using tool 380000257 to prevent the bevel pinion shaft from turning.

14. Remove the retention ball from the sleeve.

LAIL11TL0055A0A

LAIL11TL0056A0A

15. Remove pinion shaft (1) from the rear part of the box and remove the spacer, adjustment shims and bearing.

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Front axle system - Front bevel gear set and differential

16. Remove the dust seal, oil seal (1) and the rear bearing.

LAIL11TL0057A0A

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Index Front axle system - 25 Front bevel gear set and differential - 102 Bevel gear set and differential carrier - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bevel gear set and differential carrier - Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Bevel gear set and differential carrier - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Differential - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Differential - Preload - Side bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Differential lock Dog clutch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

FUNCTIONAL DATA Planetary drive and hub Exploded view - Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Wheel hub Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Axle shaft Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Planetary drive and hub Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Steering knuckle and king pin Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

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CONSUMABLES INDEX Consumable

Reference

NEW HOLLAND AMBRA GR Steering knuckle and king pin - Adjust 75 MD

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PAGE 25.3 / 27

Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Exploded view - Support

RCPH10TTS004FAF

(1) (2) (3) (4) (5) (6) (7)

Circlip Lock plate Thrust pin Stud bolt Support box Hub support screw Drain/level plug

(8) External plate (9) Cover screw to support (10) Wheel stud with support (11) Shaft (12) Thrust washer (13) Side gear (14) Bearing needles

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Sectional view

LAIL11TS0002G0A

Wheel hubs 1. 2. 3. 4.

Driven gear shims of the epicyclic unit (hub) Oil seals (casette) Hub shaft oil seal Shaft fixing bolt

5. 6. 7. 8.

Shaft Shaft oil seal Articulation pin adjustment shims Axle bush

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Disassemble 1. Remove side gears support, sun gear, spacer and thrust washer. 2. Place a suitable lifting device around the hub and the alternative housing for support during removal.

RCPH09TTS301AAD

LAIL11TL0080A0A

RCPH09TTS303AAD

LAIL11TL0029A0A

3. Remove the upper and lower setscrews (1) of the reciprocating bolts (2) and lever bolts and the calipers to remove them from the box, registering the position of each caliper. Identify upper bolt and calipers and identify lower bolts and calipers, to make mounting easier.

4. Carefully remove the hub and the reciprocating housing from the axle housing while preventing the wheel shaft from coming out of the axle housing. When removing the hub and the housing from the axle housing, hold the short end of the wheel shaft when passing through the detent.

5. Carefully remove the wheel shaft from the axle housing, guiding it through the external detent.

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Inspect 1. Look for damage or wear in the bearing and detent support area. 2. Use a sliding hammer (1) to remove the shaft detents (2) from inside of the tube.

RCPH09TTS304AAD

RCPH09TTS306AAD

RCPH09TTS307AAD

3. Remove the reciprocating housing.

4. Inspect the reciprocating housing shaft bushings and the axle housing. If the bushings (1) are damaged or word, remove them using a sliding hammer (2) and suitable attachment (3). NOTE: The wheel shaft bushing inside the reciprocating housing is held in place with an external circlip. Make sure that circlip is not damaged during dismantling.

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Install DANGER Falling parts! Keep fingers and hands clear of mating surfaces of counterweight and machine upper structure during counterweight removal and installation. Failure to comply will result in death or serious injury. D0005B

Prior operation: Axle shaft - Remove (25.108) Prior operation: Axle shaft - Inspect (25.108) 1. Mount the new detents (2) into the reciprocating housing using a pilot tool (1).

RCPH09TTS308AAD

RCPH09TTS309AAD

2. Install the bushing (2) in the axle housing using a pilot tool (1).

3. Carefully place the shaft through the axle housing and insert it in the differential side gear. Make sure the detent is not damaged. 4. Place the other end of the shaft through the reciprocating housing, passing the housing over the shaft until the shaft is housed in the axle housing. 5. Mount the reciprocating bolts and shims. Make sure the same number of shims that were removed are installed. Shims should be installed at location of removal. Make sure the detents are properly squared.

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Front axle system - Final drive hub, steering knuckles, and shafts

Prior operation: Axle shaft - Remove (25.108) Prior operation: Axle shaft - Inspect (25.108) 1. Mount the new detents (2) into the reciprocating housing using a pilot tool (1).

RCPH09TTS308AAD

RCPH09TTS309AAD

2. Install the bushing (2) in the axle housing using a pilot tool (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Four-Wheel Drive (4WD) axle - Remove (25.100) 1. Remove side gears support, sun gear, spacer and thrust washer. 2. Place a suitable lifting device around the hub and the alternative housing for support during removal.

RCPH09TTS301AAD

RCPH09TTS302AAD

RCPH09TTS303AAD

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Carefully remove the wheel shaft from the axle housing, guiding it through the external detent.

RCPH09TTS305AAD

Next operation: Axle shaft - Inspect (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Disassemble DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Raise the front of the machine and support with suitable axle stands under the front weight carrier. Remove front wheel. 2. Remove the 8 mm Allen screws (1) and the wheel studs with support (2) that fix the planetary support to the hub.

RCPH09TTS284AAD

RCPH09TTS285AAD

3. Carefully tap the planetary support with a mallet and pry up through the grooves to separate the hub support as shown.

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Front axle system - Final drive hub, steering knuckles, and shafts

4. Remove the circlip (1) from the sun gear (2) and remove the wheel shaft gear. 5. Remove the spacer (3) and the thrust washer (4).

RCPH09TTS286AAD

RCPH09TTS287AAD

RCPH09TTS288AAD

RCPH09TTS289AAD

6. Remove the eight setscrews (1) for the crown and support (2).

7. Install four of the setscrews in the crown puller threaded holes, as shown. Tighten the four setscrews (as shown) to separate the crown from the planetaries.

8. Remove the hub by carefully tapping it in equal distance places in the rear part and in the periphery with a mallet as shown.

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Front axle system - Final drive hub, steering knuckles, and shafts

9. Pry the internal track of the reciprocating housing internal bearing as shown.

RCPH09TTS290AAD

RCPH09TTS291AAD

10. Remove the circlips from the three planetary gear shafts and remove the lock plate. 11. Mark each shaft and gear so they can be matched later. 12. Remove each planetary gear, the thirty bearing rollers and the internal trust washer.

Next operation: Planetary drive and hub - Inspect (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Inspect Prior operation: Planetary drive and hub - Disassemble (25.108) 1. Inspect the main hub bearings. External tracks will still be in the hub box. If worn, remove them from box with a pilot tool. Mount new external tracks fitting them inside until they are properly seated. 2. Inspect the side gears bearings, rollers and axles. If worn, replace axle and bearings. If a roller is worn or damaged, also inspect its gear support and planetary axle for damage. 3. Hold the crown (3), remove the clamping rings (1) for the support (2) and separate the crown from the support. Look for worn crown teeth.

RCPH09TTS295AAD

RCPH09TTS296AAD

4. Inspect the crown support stud bushings to the reciprocating housing. 5. On the reciprocating housing (1) there is a replaceable detent support (2). Check if this support is worn. 6. Carefully inspect planetary shaft cover and support at their contact surfaces as well as support contact surfaces from planetary support to hub looking for wear and tear that could be repaired with abrasive stone.

(1) Wheel axle (2) Floating housing (3) Hub (4) Support (5) Stud bushing (7x20 + 1x24 mm) (6) Support setscrew Next operation: Planetary drive and hub - Install (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Planetary drive and hub - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Planetary drive and hub - Inspect (25.108) 1. Install each planetary gear, the thirty bearing rollers and the internal thrust washer. 2. Install the three planetary gears in the shafts. 3. Install the lock plate (2) and circlips (1) in the planetary gear shafts to fix the lock plate.

RCPH09TTS291AAD

RCPH09TTS287AAD

4. Mount the internal hub bearing in the reciprocating housing. Carefully install a new detent in the hub. 5. Screw in the crown and support (2) to the reciprocating housing, making sure that the biggest bushing is properly mounted. Tighten the eight setscrews (1) equally in three steps until torque meets specification.

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Front axle system - Final drive hub, steering knuckles, and shafts

6. Install the thrust washer (4) and the spacer (3). 7. Install the wheel shaft gear and install the circlip (1) in the sun gear (2).

RCPH09TTS286AAD

RCPH09TTS285AAD

RCPH09TTS284AAD

8. Grease hub and planetary support contact surfaces with specified sealant. Install the planetary support in the hub. NOTE: Hub bearings and their support inside hub box fit in very tight tolerances, so it is not necessary to adjust preload and turn resistance.

9. Install the 8 mm Allen screws (1) and the wheel studs with support (2) to fix the planetary support to the hub. Tighten the screws to specification.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Remove WARNING Avoid injury! The component is heavy. Removal/installation requires two persons or a lifting device. Failure to comply could result in death or serious injury. W1141A

1. Hold the hub and the planetary support up with an appropriate lifting device as shown..

RCPH09TTS301AAD

RCPH09TTS302AAD

2. Remove the upper and the lower reciprocating bolt setscrews and remove these parts with care.

(1) (2) (3) (4)

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Reciprocating bolt Setscrews Groove to lever Nipple

Front axle system - Final drive hub, steering knuckles, and shafts

3. Record the position of each shim. Identify the upper bolt with its shims and identify the lower shim(s).

RCPH09TTS311AAD

RCPH09TTS303AAD

4. Carefully remove the hub and steering knuckle housing from axle housing while preventing the wheel shaft from coming out of housing as shown.. When removing hub and housing from axle housing, hold short end of wheel shaft when passing through the detent.

5. Carefully remove wheel shaft from axle housing guiding it through external detent. 6. Carefully remove wheel shaft from flared tube guiding it through external detent. Next operation: Steering knuckle and king pin - Disassemble (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Disassemble Prior operation: Steering knuckle and king pin - Remove (25.108) 1. Remove the detents from their upper and external housings of the reciprocating housing.

RCPH09TTS315AAD

RCPH09TTS314AAD

RCPH09TTS316AAD

2. Using a slide hammer and suitable attachment to remove the bearing external tracks from the tube.

3. Remove the bearing cone of the reciprocating bolt.

Next operation: Steering knuckle and king pin - Assemble (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Assemble Prior operation: Steering knuckle and king pin - Disassemble (25.108) 1. Place the new bearing external cups inside the upper and lower housings of the flared tube ends with a pilot tool (as shown). NOTE: To make mounting procedure easier, it may be necessary to heat flared tube and then cool down the bearing.

RCPH09TTS317AAD

RCPH09TTS318AAD

RCPH09TTS319AAD

2. Install new detents next to each bearing cup as shown. NOTE: Detents may fit in tight until they reach their housings.

3. Place new cones in the knuckle bolts as shown, making sure they are properly seated.

(1) Spacer block (2) Bearing cone (3) Reciprocating bolt Next operation: Steering knuckle and king pin - Install (25.108)

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Replace WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Pins and spherical bushings Replacement If pins are difficult to remove, proceed as follows: 1. Remove the grease fitting and the fixing screws of the pins. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and attach it to the three bolts with nuts (5). 4. Fit the central lock bolt (4), fastening it completely into the hole in the pin's grease nipple (6). 5. Fit the nut (3) and tighten it to remove the pin.

LAIL11TL0938B0A

LAIL11TL0077A0A

6. Using the extraction tool 380000234 (1) remove the spherical bushing. 7. Install the spherical bushings using a suitable mandrel.

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Front axle system - Final drive hub, steering knuckles, and shafts

LAIL11TL0938B0A

LAIL11TL0077A0A

6. Using the extraction tool 380000234 (1) remove the spherical bushing. 7. Install the spherical bushings using a suitable mandrel.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Steering knuckle and king pin - Assemble (25.108)

Installation of bolt and lower caliper 1. Carefully mount the hub and knuckle housing on shaft and its housing on the flared tube. Make sure the shaft does not damage the detent when passing through the housing, nor damages the detents of the upper and lower reciprocating bolts. NOTE: Reciprocating bolt bearings are preloaded at 0.20 - 0.40 mm (0.008 - 0.016 in). Preload should be adjusted when installing new bearings or a new casing. When installing a new bearing, it is advisable to adjust preload to its upper limit, and when installing worn bearings, adjust preload to its lower limit. 2. Select the 10 mm (0.4 in) shim (2) and mount the lower reciprocating bolt (1) with this shim below the bolt head.

RCPH09TTS320AAD

RCPH09TTS321AAD

3. Without installing shims, mount the upper knuckle bearing. Tighten the upper and lower knuckle bearings to specified torque. 4. Mount a gauge with the end on the upper part of the upper knuckle bolt and with the body fixed to the tube as shown.

5. Place the dial to zero and pry up the knuckle housing. With the 10 mm (0.4 in) shim in lower bolt, a certain free play is achieved. Record the free play.

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Front axle system - Final drive hub, steering knuckles, and shafts

6. Add the specified preload to the registered measurement and subtract the already mounted shim total of 10 mm (0.4 in). The result will be the total thickness to achieve specified preload. The result of this thickness should then be divided into two equal parts to distribute between upper and lower bolt. Refer to the equation and the example that follows to determine the spacer. S = [C - (A + B)]/2, where S = Shim to be placed on each pivot cone. C = Shim or benchmark of 10 mm (0.4 in) A = Measured or registered free play on the gauge B = Specified preload range 0.20 - 0.40 mm (0.008 - 0.016 in). When installing a new bearing, it is advisable to adjust preload to its upper limit, and when installing worn bearings, adjust preload to its lower limit. Example (in mm): S=? C = 1.0 A = 0.20 measured free play B = 0.40 for new bearings S = [1.0 - (0.20 + 0.40)]/2 S = 0.40/2 S = 0.20 mm for each bolt 7. Remove the reciprocating bolts (1), figure 1, and the 1.0 mm (0.04 in) shim (2) figure 1, of the lower bolt. 8. Install the newly calculated shim for each bolt and tighten to specification.

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Front axle system - Final drive hub, steering knuckles, and shafts

LAIL11TL0938B0A

LAIL11TL0077A0A

6. Using the extraction tool 380000234 (1) remove the spherical bushing. 7. Install the spherical bushings using a suitable mandrel.

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust Adjusting the steering casing DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Put the front drive on a stand for service 293460 and proceed as follows.

LAIL11TL0078A0A

LAIL11TL0079A0A

LAIL11TL0080A0A

1. Apply grease NEW HOLLAND AMBRA GR 75 MD on the outer track of the bushing and fit the upper pin without the adjustment shims using tool 380000235 (2). Tighten the fixing bolts with a torque of 64 N路m (47.2 lb ft) in the TL60E model (CNH Class I HD shaft) or 113 N路m (83.3 lb ft) in models TL75E, TL85E and TL95E (CNH class II shaft). NOTE: To make it easier to install the casing, we recommend that guide 293889 (1) be installed. 2. Fit the lower pin without adjustment shims and lubricate the three mounting bolts with engine oil.

3. Gradually tighten the lower screws in sequence, turning the casing to allow excess grease to drain out. 4. With a torque wrench and the 380000235 (1) tool, check that the torque required to turn the housing is 2.9 N路m (2.1 lb ft) for the TL60E model (CNH Class I HD shaft) or 15 - 25 N路m (11.1 - 18.4 lb ft) for the TL75E, TL85E and TL95E models (CNH class II shaft), ignoring the initial peak value. If the value is different, make an adjustment using the screws on the pin's lower flange. 5. Measure the distance (H) between the bottom flange of the pin and the casing, in relation to the three bolts.

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Front axle system - Final drive hub, steering knuckles, and shafts

6. Calculate the average of the three measured values. The total thickness of the "S3" adjustment shim to be inserted under the flange of the lower pin must be calculated as follows:

LAIL11TL0081A0A

S3 = H - 0.20 mm. If necessary, round the values to the nearest 0.05 mm . 7. Partially loosen the screws on the flange of the lower pin and insert the shims. Tighten the bolts with a torque of 64 N路m (47.2 lb ft) in the TL60E model (CNH Class I HD shaft) or 113 N路m (83.3 lb ft) in models TL75E, TL85E and TL95E (CNH class II shaft). 8. After turning the housing a number of times to ensure the components are seated, check that the torque required to turn the housing is 2.9 - 7.8 N路m (2.1 - 5.8 lb ft)for the TL60E model (CNH Class I HD shaft) or 118 - 147 N路m (87 - 108 lb ft) for models TL75E, TL85E and TL95E (CNH class II shaft), ignoring the initial peak value. 9. If the measured torque value is higher than the recommended value, increase the shim thicknesses: if the measured value is lower than the recommended value, reduce the shim thicknesses. 10. Install the grease nipples in the flanges of the top and bottom pins and lubricate the set.

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108 Axle shaft - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Axle shaft - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Axle shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Axle shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Axle shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Planetary drive and hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Planetary drive and hub - Exploded view - Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary drive and hub - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Planetary drive and hub - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Steering knuckle and king pin - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering knuckle and king pin - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Steering knuckle and king pin - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Steering knuckle and king pin - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Steering knuckle and king pin - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Steering knuckle and king pin - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Steering knuckle and king pin - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Steering knuckle and king pin - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Wheel hub - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Rear axle system

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3 [27.124] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.4

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Rear axle system - 27 Powered rear axle - 100

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Powered rear axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Rear axle Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Powered rear axle Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Rear axle Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Powered rear axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Rear axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIAGNOSTIC

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Powered rear axle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

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Rear axle system - Powered rear axle

Powered rear axle - General specification

LAIL11TS0201A0A

Side gears Spiral gear ratios Planetaries Toral Diameter of bypass, spiral gear Axle diameter Differential lock Draft bars Load capacities Oil specification Oil capacity

3 5.286 4.5 23.786 333.5 mm (13 in) 66.58 mm (2.6 in) Mechanical 4082 kg (8999 lb) 5443 kg (12000 lb) Multi-G Ambra 66 l (17.4 US gal)

Powered rear axle - Torque Components Rear disc to hub nuts (manual adjust wheels) Rear disc to rim nuts (manual adjust wheels) Buckle-up bolts Differential case retaining bolts Drive pinion bearing retainer bolts Planetary gear retaining bolts Axle shaft housing retaining bolts Axle shaft retaining bolts Differential ring gear retaining bolts Differential lock fork pivot shaft retaining bolts Differential lock hanger retaining bolts Inner brake housing retaining bolts

407 - 475 N·m (300 - 350 lb 310 - 340 N·m (229 - 251 lb 240 - 298 N·m (177 - 220 lb 92 - 125 N·m (68 - 92 lb ft) 136 - 170 N·m (100 - 125 lb 339 - 542 N·m (250 - 400 lb 176 - 258 N·m (130 - 190 lb 339 - 542 N·m (250 - 400 lb 115 N·m (85 lb ft) 57 - 76 N·m (42 - 56 lb ft) 57 - 76 N·m (42 - 56 lb ft) 88 - 121 N·m (65 - 89 lb ft) 73403953 04/04/2014

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ft) ft) ft) ft) ft) ft) ft)

Rear axle system - Powered rear axle

Ring gear thrust block Power adjust wheels

37 - 50 N·m (27 - 37 lb ft) 712 N·m (525 lb ft)

Powered rear axle - Special tools NOTE: To work efficiently and safely and to obtain the best results, use the tool specifically recommended for this purpose.

Special tools List of specific tools required for the various operations described in this section. 297471 Kit to disassemble the tractor

Powered rear axle - Torque Components Axle housing fixing bolts Shaft fixing bolt Differential gear fixing nuts Differential box fixing bolts Differential lock fork pivot shaft fixing bolts Differential lock support fixing bolts Internal brake housing fixing bolts Pinion bearing retainer bolts Transmission housing bolts Differential gear drive block Wheel nuts (disk to hub) Manual Adjustment Wheels Mechanical Adjustment Wheels

Nm 17.6 - 25.8 N·m 33.9 - 54.2 N·m 11.5 N·m 9.2 - 12.5 N·m 5.7 - 7.6 N·m

Kgf/m 1.76 - 2.58 kgf 3.39 - 5.42 N·m 1.15 kgf 0.92 - 1.25 kgf 0.57 - 0.76 kgf

5.7 - 7.6 N·m 8.8 - 12.1 N·m 13.6 - 17 N·m 200 N·m 3.7 - 5 N·m

0.57 - 0.76 kgf 0.88 - 1.21 kgf 1.36 - 1.7 kgf 20 kgf 0.37 - 0.5 kgf

39 N·m 71.2 N·m

3.9 kgf 7.12 kgf

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Rear axle system - Powered rear axle

Rear axle - Calibration Preload Axle spin torque with a pull scale: 11.6 - 28.2 N·m (8.6 - 20.8 lb ft)

Resulting number 1.24 1.35 1.45 1.55 1.65 1.75 1.85 1.96 2.06 2.16 2.26

1.32 mm 1.42 mm 1.52 mm 1.63 mm 1.73 mm 1.83 mm 1.93 mm 2.03 mm 2.13 mm 2.24 mm 2.34 mm

(0.05 - 0.052 in) (0.053 - 0.056 in) (0.057 - 0.060 in) (0.061 - 0.064 in) (0.065 - 0.068 in) (0.069 - 0.072 in) (0.073 - 0.076 in) (0.077 - 0.080 in) (0.081 - 0.084 in) (0.085 - 0.088 in) (0.089 - 0.092 in)

Spacer to be installed 1.14 mm 1.25 mm 1.35 mm 1.45 mm 1.55 mm 1.65 mm 1.75 mm 1.85 mm 1.96 mm 2.06 mm 2.16 mm

(0.04 in) (0.05 in) (0.053 in) (0.057 in) (0.061 in) (0.065 in) (0.069 in) (0.073 in) (0.077 in) (0.081 in) (0.085 in)

Rear axle - Torque Components Axle housing fixing bolts Shaft fixing bolt Differential gear fixing nuts Differential box fixing bolts Differential lock fork pivot shaft fixing bolts Differential lock support fixing bolts Internal brake housing fixing bolts Pinion bearing support bolts Differential gear drive block Wheel nuts (disk to hub) Manual Adjustment Wheels Mechanical Adjustment Wheels

Kgf/cm2 17.6 - 25.8 Kg/cm² 33.9 - 54.2 Kg/cm² 11.5 Kg/cm² 9.2 - 12.5 Kg/cm² 5.7 - 7.6 Kg/cm² 5.7 - 7.6 Kg/cm² 8.8 - 12.1 Kg/cm² 13.6 - 17 Kg/cm² 3.7 - 5 Kg/cm² 39 Kg/cm² 71.2 Kg/cm²

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Rear axle system - Powered rear axle

Powered rear axle - Component identification Description and operation The rear axle has mechanical breaks and a mechanical differential lock. The rear axle, connected to the rear part of the transmission, connects the engine control and the gear box to the rear wheels. Inside the rear axle you will find these components: • Pinion and differential crown • Differential • Differential lock • Brakes • Gears and final reduction • Wheel axles • PTO components • Transmission emergency brake • Variable displacement or tandem gear hydraulic pumps Gearing from the output drive shaft passes through a pinion with helicoidal teeth and through a coupling control. The pinion is found in the front part of the rear axle and is supported by two preloaded tapered roller bearings that make contact with the differential crown. The crown is riveted to the differential casing, which is supported between tapered bearings, that are mounted on the rear axle housing. NOTE: When in service, the crown rivets are replaced with screws and nuts.

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Rear axle system - Powered rear axle

Powered rear axle - Exploded view (1) External brake housing (2) Axle housing external bearing (3) Axle shaft (4) Axle shaft oil seal (5) Side gear carrier (6) Axle housing (7) Brake torque pin (8) Differential assembly (9) PTO drive and driven gears (10) PTO rear shaft (11) Differential lock assembly (12) Rear wheel brake assembly

(13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

Side gears Axle housing internal bearing Sun gear Differential lock fork Drive pinion Drive pinion locknut Rear axle center housing Pinion bearing retainer Differential ring gear Thrust box Inner brake housing

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Rear axle system - Powered rear axle

RCPH09TTS001GAF

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Rear axle system - Powered rear axle

Powered rear axle - Overview Description and operation The rear axle of tractors of 8 X 2 or 16 X 4 transmissions have mechanical brakes and mechanical differential lock. It is linked to the rear part of the transmission and links the engine and the gear box to the rear wheels. Housed inside the rear axle assembly are the following components: • Pinion and differential gear. • Differential. • Differential lock set. • Brakes. • Final reduction gears. • Wheel shafts. • Power Take Off (PTO) Components. • Hand brake to transmission. • Main hydraulic pumps (double gears). The transmission output shaft drive is transmitted to the helical bevel pinion by the drive coupling. The pinion is situated forward of the rear axle housing and is supported by two pre-loaded conical ball bearings, and is in contact with the differential gears. The differential gear is riveted to the differential box, which is supported between the ball bearings installed in the rear axle housings. NOTE: In service, the differential gear rivets are replaced by nuts and bolts. There is a drive block installed in the heavy duty shaft to prevent the differential gear from moving due to the pre-load of the drive pinion. The block mould also assures the passage of an adequate quantity of lubricating oil to the drive pinion bearings. The axle housings work with higher oil levels than the differential box. The left side of the differential box and the wheel shaft housing on the right side have restrictions to maintain the high levels, The differential box is formed by two halves that are bolted together. They include the differential spider and the lateral gears. The pinion drive is transmitted by means of the differential gear and the differential box to the spider arms. There are pinion gears in the spider, which are in constant gear with the two side gears. The intermediate shaft is striated in each side gear and the brakes are striated for these shafts. The external end of each intermediate shaft forms the sun gear of an epicyclical final reduction installed in each shaft housing. The wheel drive is transmitted from the intermediate shaft to the external shaft by the reduction gear. The internal ends of the shaft are striated on the planetary gear carrier. The wheel shafts are supported by conical ball bearings installed in each shaft housing. The oil supplied to the PTO and the hydraulic systems are also used in the rear axle components. The differential assembly and the differential gear are partially immersed in oil to provide lubrication for the bearings and bushings.

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Rear axle system - Powered rear axle

Rear axle - Component identification • There is a thrust block mounted on the axle to keep the ring gear from flexing during drive pinion preload. The thrust block also ensures that some lubricating oil passes through to the drive pinion bearings. • The axle shaft housings receive a larger amount of oil than the center housing. The left hand (1) and the right hand (2) axle housing have restrictions (3) to maintain the higher levels.

RCPH09TTS392AAD

RCPH09TTS393AAD

Example: Left hand oil restrictor (1) Rear axle center housing (2) Plastic plug

• The differential case assembly forms two halves which bolt together to enclose the differential crosshead and the side gears. • The drive from the pinion transmits through the ring gear and the differential cases assembly to the crosshead. Pinion gears mounted on the crosshead are in constant mesh with the side gears. • The brake assemblies mount on the spline end of the intermediate shafts. The intermediate shafts spline into the side gears. • The outer end of each intermediate gear forms the sun gear of an epicyclic final reduction gear set and is mounted within the axle housings. • A reduction gear set transmits drive to the wheels from the intermediate shaft to the axle shaft. • The side gear carrier mounts to the inner spline of the exterior axle shaft. Tapered roller bearings, which are installed in each axle housing, support the axle shafts. • The hydraulic system oil lubricates the rear axle components. The differential ring gear assembly is partially submerged in oil to provide splash feed lubrication to the bearings and bushings.

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Rear axle system - Powered rear axle

Powered rear axle - Remove Splitting the transmission, engine and front support from the rear axle WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

1. Remove the fuel tank (see removing the fuel tank in the fuel system chapter in the engine section). 2. Disconnect the electric harness as necessary to allow splitting the transmission from the rear axle. 3. Use an appropriate cable to connect a block and tackle to the front weights and remove them (if installed).

LAIL11TS0019A0A

LAIL11TS0082A0A

LAIL11TS0090A0A

4. Remove the front wheel drive driveshaft shield. 5. Expand and slide the lock ring (1) and the sleeve (2) over the front wheel drive driveshaft.

6. Remove the front wheel drive driveshaft and the central support.

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Rear axle system - Powered rear axle

7. Position wooden wedges (1) between the front axle and the front support. This prevents axle articulation.

LAIL11TS0106A0A

LAIL11TS0202A0A

ATTENTION: Ensure the transmission and rear axle sections are fully supported to prevent any movement when the transmission is removed. 8. Position the splitting kit (3) 297471 under the tractor. 9. Use the support (2) in the splitting kit to support the rear axle on the platform for splitting. 10. Use the support (1) in the splitting kit to support the rear axle on the cart for splitting.

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Rear axle system - Powered rear axle

11. Check if all necessary hoses and electric connectors have been disconnected. It may be necessary to disconnect additional items due to other optional equipment that was installed on the tractor. 12. Remove the fixing bolts from the transmission to the rear axle. 13. Remove the transmission and the engine from the rear axle.

LAIL11TS0203A0A

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Rear axle system - Powered rear axle

Powered rear axle - Install Installation of the transmission, engine and front support to the rear axle WARNING Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply could result in death or serious injury. W0398A

ATTENTION: Ensure the transmission and rear axle sections are fully supported to prevent any movement when the transmission is removed.

LAIL11TS0201A0A

LAIL11TS0090A0A

LAIL11TS0082A0A

1. Thoroughly clean and degrease all the contact surface and apply a string of liquid gasket of approx. 2 mm in diameter following the pattern shown. 2. Align the transmission to the rear axle and install the fixing bolt from the transmission to the rear axle. Tighten to the specified torque value. 3. Install the front wheel drive driveshaft and the central support.

4. Expand and slide the lock ring (1) and the sleeve (2) over the front wheel drive driveshaft. 5. Install the front wheel drive driveshaft shield.

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Rear axle system - Powered rear axle

6. Use an appropriate cable to connect a block and tackle to the front weights and install them (if installed). 7. Connect or install the electric harness. 8. Install the fuel tank (see installing the fuel tank in the fuel system chapter in the engine section).

LAIL11TS0019A0A

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Rear axle system - Powered rear axle

Rear axle - Remove WARNING Jack stands can slip or fall over. Dropping, tipping, or slipping of machine or its components is possible. DO NOT work under a vehicle supported by jack stands only. Park machine on a level surface. Block wheels. Support machine with safety stands. Failure to comply could result in death or serious injury. W0069A

1. Block the front wheels and engage the emergency brake. 2. Empty the oil from the rear axle and disconnect the lift braces. 3. Disassemble the automatic hook braces, emergency brake cables and hydraulic brake piping or linkage to brake pedals. 4. Remove the rear wheels. Replace the nuts on the studs to avoid damage. 5. Supporting the axle housing with a traversing jack, remove the setscrews and separate the axle housing from the machine. RCPH09TTS400AAD

Next operation: Rear axle - Disassemble (27.100)

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Rear axle system - Powered rear axle

Rear axle - Disassemble Prior operation: Rear axle - Remove (27.100) 1. Remove the large O-ring in the inside end of the axle housing. 2. If removing the right axle housing, remove the differential assembly to avoid damaging anything during the parts breakdown of the axle. 3. Remove the two hydraulic brake tubes from the housing and the screws that fix the inner brake, then remove the inner brake housing from the axle housing. 4. Remove the friction brake discs and the drive disc. Lift the sun gear and the intermediate shaft out of the axle and remove the outer brake housing. 5. Remove the security setscrew from the wheelâ&#x20AC;&#x2122;s axle and the screw.

RCPH09TTS401AAD

RCPH09TTS402AAD

NOTE: It may be necessary to heat the locking tab in order to remove the sealant applied during production. 6. Remove the planet (side) gear assembly (2) from the axle housing with a puller (1). Remove and save the shim and washer from underneath the gear assembly.

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

NOTE: When removing the side gear and the axle housing support, make sure that the puller is correctly placed. Do not attempt to remove or change the set without using the correct puller. Doing so may cause an accident. 7. Remove the axle shaft and inner bearings from the housing. 8. Repeat for the opposite axle housing. Next operation: Rear axle - Disassemble (27.100)

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Rear axle system - Powered rear axle

Rear axle - Visual inspection CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Rear axle - Disassemble (27.100) 1. Inspect all components for damage or wear. Replace as required. 2. If removal of the outer cone and roller assembly (3) of the axle shaft is necessary, use the pulley (1) with legs (4) and a suitable attachment (2), and use the shaft protector.

RCPH09TTS406AAD

RCPH09TTS407AAD

3. Install the shaft seal, followed by the bearing assembly, using a suitable pipe and press. 4. If necessary, use the sliding hammer (1) with a suitable attachment to remove the bearing cup (3) from the outer end of the axle housing (2). To replace the bearing cup, use a step plate and a mallet. Seat the bearing cup completely in the axle housing.

Next operation: Rear axle - Assemble (27.100)

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Rear axle system - Powered rear axle

Rear axle - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Rear axle - Remove (27.100) Prior operation: Rear axle - Disassemble (27.100) Prior operation: Rear axle - Visual inspection (27.100) Assemble the rear axle as follows: 1. Make sure that the brake actuators (1) and the hydraulic hoses are properly installed. The left actuator piping goes towards the hub of the wheel. The right actuator hub goes above, towards the filter.

RCPH09TTS408AAD

2. Install the axle shaft and inner bearings onto the housing. 3. Install the shim and washer onto the underside of the gear assembly, then install the planet (side) gear assembly (2) onto the axle housing. 4. Remove the security setscrew from the wheelâ&#x20AC;&#x2122;s axle and the screw. 5. Install the sun gear and the intermediate shaft into the axle and install the outer brake housing. Install the friction brake discs and the drive disc. 6. Install the inner brake housing onto the axle housing, then install the two hydraulic brake tubes onto the housing and the screws that fix the inner brake.

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Rear axle system - Powered rear axle

7. If the right axle housing was removed, install the differential assembly to avoid damaging anything during the parts breakdown of the axle.

RCPH09TTS401AAD

8. Remove the large O-ring in the inside end of the axle housing. 9. Repeat for the opposite axle housing. Next operation: Rear axle - Install (27.100)

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Rear axle system - Powered rear axle

Rear axle - Install CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Rear axle - Remove (27.100) Prior operation: Rear axle - Assemble (27.100) 1. Install the rear axle shaft assembly in the reverse order of removal, with these requirements: 2. Apply wheel bearing grease to the axle retainer, taper and bearing. 3. Adjust the axle bearing preload. Preload (27.100) .

See Rear axle -

4. Adjust the differential bearing preload. Refer to Differential - Preload (27.106) if any of the following components have been changed: • Planetary ring gear • Outer brake housing • Inner brake housing • Differential housing • Shaft housing 5. Tighten all nuts and screws to their correct torque. 6. Check and, if necessary, adjust the brake pedals in the mechanical system and the emergency brake. Next operation: Rear axle - Preload (27.100)

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Rear axle system - Powered rear axle

Rear axle - Preload Prior operation: Rear axle - Install (27.100) 1. Install the axle into the axle housing. 2. Install the inner bearing cone and roller assembly on the axle shaft. Using a suitable sized pipe, tap the bearing into the axle shaft. DO NOT set the bearing completely over its housing. 3. Install the larger 2.16 mm (0.09 in) spacer onto the axle and mount the planetary gear carrier in the axle housing.

RCPH09TTS420AAD

RCPH09TTS421AAD

4. Install and tighten the support set screws to a torque of 339 - 542 N·m (250 - 400 lb ft). 5. Position the comparator dial (2) and adjust to zero. 6. Measure the play by lifting the axle housing (1). 7. Subtract the amount of play from the size of the installed spacer to determine the correct size of the spacer to be mounted. Refer to the following example. • Installed spacer: 2.16 mm (0.09 in) • Obtained reading: 0.66 mm (0.03 in) • Resulting number: 1.50 mm (0.06 in)

Resulting number 1.24 1.35 1.45 1.55 1.65 1.75 1.85 1.96 2.06 2.16 2.26

1.32 mm 1.42 mm 1.52 mm 1.63 mm 1.73 mm 1.83 mm 1.93 mm 2.03 mm 2.13 mm 2.24 mm 2.34 mm

(0.049 (0.053 (0.057 (0.061 (0.065 (0.069 (0.073 (0.077 (0.081 (0.085 (0.089

0.052 in) 0.056 in) 0.060 in) 0.064 in) 0.068 in) 0.072 in) 0.076 in) 0.080 in) 0.084 in) 0.088 in) 0.092 in)

Spacer to be installed 1.14 mm 1.24 mm 1.35 mm 1.45 mm 1.55 mm 1.65 mm 1.75 mm 1.85 mm 1.96 mm 2.06 mm 2.16 mm

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(0.045 in) (0.049 in) (0.053 in) (0.057 in) (0.061 in) (0.065 in) (0.069 in) (0.073 in) (0.077 in) (0.081 in) (0.085 in)

Rear axle system - Powered rear axle

8. Remove the set screw from the axle and remove the planetary gear carrier assembly (1), the safety washer and the large spacer. 9. Install the newly selected spacer and then install the safety washer and the planetary gear carrier assembly. 10. Install the set screw and tighten to a torque of 339 542 N·m (250 - 400 lb ft).

11.

RCPH09TTS421AAD

RCPH09TTS422AAD

After shimming is complete, measure the axle shaft rolling torque. A. Fabricate a plate (1), with a bolt head or nut welded in the center, to slide over the wheel studs (2). Plate specifications: • (A) 51 mm (2 in) • (B) 101.6 mm (4 in) • (C) 101.6 mm (4 in) • (D) 22 mm (0.875 in) diameter

B. Using a suitable torque wrench, check the rolling torque. Specification is 11.6 - 28.2 N·m (8.6 20.8 lb ft). C. Add or remove shims as needed.

12. Repeat for opposite-side rear axle shaft.

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Rear axle system - Powered rear axle

Rear axle - Remove Removal NOTICE: Before dismounting, make sure that the hand brake is activated and the front wheels blocked to prevent the machine from moving. 1. Drain the oil from the rear axle of the central housing and switch of the hydraulic lift connecting rods. Dismount the automatic union connecting rods, hand brake cables and foot brake tubes. 2. Dismount the rear wheels, replace the nuts on the bolts to prevent damage to the nut threads during servicing. 3. Support the rear axle housing (1) with a trolley jack (2). Remove the fixation bolts and dismount the tractor axle housing, Figure 1.

LAIL11TS0089A0A

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Rear axle system - Powered rear axle

Rear axle - Disassemble Dismounting 1. Remove the large seal ring from the inside end of the shaft housing. 2. If the immediate housing has been disassembled, dismantle the differential (1) to avoid damage during shaft maintenance, Fig. 1. 3. Remove the friction disk assemblies from the brake and the actuator disk. Remove the intermediate shaft from the sun gear shaft and then remove the internal brake housing. 4. Remove the retention bolt locking tab from the shaft and bolt. LAIL11TS0091A0A

LAIL11TS0092A0A

LAIL11TS0093A0A

NOTE: You may need to warm the locking tab to clear the seal used in production. 5. Lift the planetary gear and the transporter assembly (2) with extractor No. 943 (1), expanded under the planetary gear, Fig. 2. Remove the shim from under the transporter. NOTE: When lifting the planetary gear assembly and the housing transporter from the shaft check that the extractor is well positioned. Do not try to remove or replace the assembly without the correct extractor, as this may cause personal injury.

6. Remove the shaft from the housing. To help with disassembly, a Tool can be made. Use of the Tool and its dimensions are shown in Figure 3 and 4

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Rear axle system - Powered rear axle

LAIL11TS0094A0A

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Rear axle system - Powered rear axle

Powered rear axle - Troubleshooting Problem Noisy rear axle

Does not move (Also refer to clutch system troubleshooting)

Possible Cause Lack of oil Incorrect specification of oil Worn out axle bearings Axle shaft housing defective

Differential unit components defective

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Correction Refill to oil specification Empty and refill to correct oil specification Dismantle and inspect bearings Operate the tractor; if the tractor drives, inspect the axle shaft housing components and overhaul Operate the tractor; if the tractor does not drive, inspect the differential unit components and overhaul

Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Powered rear axle - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Powered rear axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Powered rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Powered rear axle - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Powered rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Powered rear axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered rear axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Rear axle - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Rear axle - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear axle - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Rear axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Rear axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Rear axle - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear axle - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Rear axle system - 27 Rear bevel gear set and differential - 106

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

TECHNICAL DATA Differential Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Differential Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Differential lock Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Differential lock hydraulic control Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Disassemble - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Inspect - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Preload - Drive pinion bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Differential lock hydraulic control Differential lock hydraulic control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Differential lock hydraulic control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Differential lock hydraulic control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Differential lock hydraulic control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Differential lock hydraulic control - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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DIAGNOSTIC Differential lock Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

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Rear axle system - Rear bevel gear set and differential

Differential - Calibration Differential bearing preload Spin torque of differential bearing with pull scale: 7 - 30 kgf (15.43 - 66.14 lbf)

Resulting number 0.61 0.76 0.91 1.07 1.22 1.37 1.50 1.65

0.74 mm 0.87 mm 1.04 mm 1.19 mm 1.35 mm 1.50 mm 1.63 mm 1.78 mm

(0.024 (0.030 (0.036 (0.042 (0.048 (0.054 (0.059 (0.065

0.029 in) 0.034 in) 0.041 in) 0.047 in) 0.053 in) 0.059 in) 0.064 in) 0.070 in)

Spacer to be installed 0.97 1.12 1.27 1.42 1.58 1.73 1.88 2.03

1.02 mm 1.17 mm 1.32 mm 1.47 mm 1.63 mm 1.78 mm 1.93 mm 2.08 mm

(0.038 (0.044 (0.050 (0.056 (0.062 (0.068 (0.074 (0.080

0.040 in) 0.046 in) 0.052 in) 0.058 in) 0.064 in) 0.070 in) 0.076 in) 0.082 in)

Final drive pinion preload Drive pinion preload tool Pull scale

1.1 - 1.9 NÂˇm (0.8 - 1.4 lb ft) 5.90 - 10.50 kgf (13.01 - 23.15 lbf)

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Rear axle system - Rear bevel gear set and differential

Differential - Exploded view

RCPH09TTS002FAF

(1) (2) (3) (4) (5) (6) (7) (8)

Cone and roller assembly Ring gear and housing assembly Side gear Pinion gear assembly Side gear Differential case Cone and roller assembly Coupling

(9) Differential lock ring (10) Stop washer (11) Spring (12) Adapter (13) Retaining bolt (14) Thrust washer (15) Thrust washer (16) Thrust washer

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Rear axle system - Rear bevel gear set and differential

Differential - Exploded view - Drive pinion

RCPH09TTS003FAF

(1) (2) (3) (4)

Pinion shaft Bearing, roller Fastening ring Bearing, conical roller

(5) (6) (7) (8)

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Bearing, conical roller Locknut Lock washer Retainer bearing

Rear axle system - Rear bevel gear set and differential

Differential lock - Overview The machines are equipped with a differential lock system to avoid wheel slippage. For example, if working on soft terrain and one of the wheels begins to slide, all of the machine’s force is transferred to that wheel and the machine does not move. The differential lock assembly is installed on the left side of the crown wheel and overcomes machine wheel slippage by connecting one of the side gears to the differential case assembly. This way, the differential is joined and it has direct control over both wheels. The differential lock is made up of • a sliding coupling (3) connected to the spline of the side gear. • an adaptor (2) positioned between the coupling and the left hand differential case (1). • a spring (4) positioned between the coupling and the adapter. The spring ensures the coupling only enters the adaptor when necessary and that the adaptor trigger and the differential casing are not permanently connected. • a fork and lever assembly (not shown). The fork and the lever work by means of a foot activated spring. When the fork moves, it forces the coupling’s trigger teeth into the adaptor, resulting in the joining of the lateral gear to the differential casing. Once the differential lock of the mechanical drive has been connected, the operator may take the foot off the pedal.

RCPH09TTS398AAD

The mechanical differential lock is automatically disconnected when the pressure from the spring rises above the lateral force from the coupling teeth. This only happens when the torque is equal in both wheels. NOTICE: Avoid using the differential lock at speeds greater than 8 km/h (5 mph) or when the machine is turning. Engaging the lock causes problems in machine's steering. NOTICE: If one of the rear wheels begins to slide, reduce the motor’s speed before connecting the differential block in order to avoid damaging the transmission.

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Exploded view Differential lock activation pedal:

BRAG11TRCNH0151

Pedal

Floor panel cover

Counter nut

Pedal rod

Locking ring

Axle rod

Bushings (2)

Support

Support pivot pin

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Rear axle system - Rear bevel gear set and differential

Differential - Remove DANGER Unexpected movement! Make sure parking brake is applied. Secure machine with wheel chocks. Failure to comply will result in death or serious injury. D0013A

1. Chock the front wheels to prevent movement. Release the hand brake. 2. Drain the oil from the rear axle center casing. 3. Disconnect hydraulic lift rods, automatic pick-up hitch tie rods, hand brake cables and foot brake linkage.

DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A

4. Safely raise and support the machine to accommodate removal of the right hand wheel and axle shaft housing assembly. 5. Remove the fender and roll over protection devices, if applicable, and remove the right hand rear wheel. Install nuts onto studs to prevent damage to the stud threads during overhaul. 6. Support the right hand axle shaft housing on a suitable trolley jack. Remove the retaining bolts and then separate the axle housing from the machine. 7. Remove the differential assembly from the housing. Next operation: Differential - Disassemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Disassemble Prior operation: Differential - Remove (27.106)

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(1) Cone and roller assembly (2) Ring gear and housing assembly (3) Side gear (4) Pinion gear assembly (5) Side gear (6) Differential case (7) Cone and roller assembly (8) Coupling

1. Remove the differential lock ring (9) from the end of the side gear. Remove the stop washer (10), coupling (8), spring (11) and the adapter (12). 2. Mark the two halves of the differential casing in order to facilitate its correct mounting. 3. Remove the cone and roller from the smaller half of the casing using puller with a suitable attachment and a step plate. 4. Remove the set screws from the differential casing. NOTE: If changing the taper and roller in the smaller half of the casing is unnecessary, dismantling of the casing screws can be done by lifting the smaller half of the casing and gradually removing the screws. 5. Separate the differential casing. 6. Remove the thrust washer, lateral gear, crosshead, pinion, lateral gear and casing washer. 73403953 04/04/2014

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(9) Differential lock ring (10) Stop washer (11) Spring (12) Adapter (13) Retaining bolt (14) Thrust washer (15) Thrust washer (16) Thrust washer

Rear axle system - Rear bevel gear set and differential

7. Remove the cone and roller (1) from the ring gear half of the casing using a puller with a suitable attachment and a step plate (as shown). 8. Separate pinions from crosshead.

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Next operation: Differential - Inspect (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Inspect Prior operation: Differential - Disassemble (27.106) 1. Clean and inspect all components for damage or excessive wear. Replace as needed. 2. If replacing a differential ring gear, proceed as follows: A. Drill out the rivets installed during production. B. Install bolts and nuts. C. Tighten the bolts to a torque of 115 NÂˇm (85 lb ft). D. Install a new, matching drive pinion assembly with the new ring gear. Next operation: Differential - Assemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Assemble Prior operation: Differential - Inspect (27.106) Assemble the differential in the reverse order of disassembly, with these requirements: 1. Coat all bearings with suitable grease before installing. 2. To correctly install the retaining ring after the pilot bearing on the pinion shaft, place the ring into the groove, and use pliers to form the ring into the groove. 3. Tighten the differential case retaining bolts to a torque of 92 - 125 NÂˇm (68 - 92 lb ft). Next operation: Differential - Install (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Install Prior operation: Differential - Assemble (27.106) Install the differential in the reverse order of removal, with this requirement: 1. Check and adjust the differential bearing preload. See Differential - Preload (27.106) . Next operation: Differential - Preload (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Preload The preload of the bearing is adjusted by adding or taking away spacers between the differential bearing cup and the inner brake housing. It is adjusted through the right hand axle shaft housing. 1. Mount the lower brake disk into the axle housing, without the intermediate axle, brake disks or actuator. 2. Remove the differential bearing cup and spacer from the inner brake housing. 3. Place the gauge of the bearing preload tool where the bearing is missing. 4. Fix the bridge of the bearing preload tool from the buckle in the inner brake housing, making sure the spacers stay between the buckle and the implement. 5. With the gauges, measure the separation between the front part of the bridge and the top side of the gauge block. 6. Determine the size of spacer to use. See table below. LAIL11TS0097A0A

0.61 0.76 0.91 1.07 1.22 1.37 1.50 1.65

Clearance measurement 0.74 mm (0.024 - 0.029 in) 0.87 mm (0.030 - 0.034 in) 1.04 mm (0.036 - 0.041 in) 1.19 mm (0.042 - 0.047 in) 1.35 mm (0.048 - 0.053 in) 1.50 mm (0.054 - 0.059 in) 1.63 mm (0.059 - 0.064 in) 1.78 mm (0.065 - 0.070 in)

0.97 1.12 1.27 1.42 1.58 1.73 1.88 2.03

1.02 mm 1.17 mm 1.32 mm 1.47 mm 1.63 mm 1.78 mm 1.93 mm 2.08 mm

7. Remove the bearing preload tool. 8. Install the new, selected spacer and reinstall the bearing. 9. Check the spin torque of the differential. NOTE: It is very important to test the spin torque since the bridge of the preload tool only identifies the initial size of the spacer. 10. Remove the left axle housing, if it has not already been removed. 11. Remove the pinion and the bearing retainer.

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Spacer to be installed (0.038 - 0.040 in) (0.044 - 0.046 in) (0.050 - 0.052 in) (0.056 - 0.058 in) (0.062 - 0.064 in) (0.068 - 0.070 in) (0.074 - 0.076 in) (0.080 - 0.082 in)

Rear axle system - Rear bevel gear set and differential

12. Remove the differential lock spring and place the differential lock coupling in the connection position (1). 13. With the differential installed and the buckle from the right inner brake housing screwed into the differential housing, install one of the intermediate control axles (2) in the differential. 14. Install a dynamometric scale around the intermediate axle (3). Measure spin torque while the shaft is spinning. Do not measure when the shaft first begins to spin. The rolling spin torque measured by the pull scale must be 7 - 10 kgf (15.43 - 22.05 lbf). 15. If necessary, add or remove spacers to adjust the spin torque.

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RCPH09TTS424AAD

Rear axle system - Rear bevel gear set and differential

Differential - Remove - Drive pinion DANGER Heavy parts! Support designated component(s) with adequate lifting equipment. Failure to comply will result in death or serious injury. D0018A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Differential - Preload (27.106) 1. Separate the machine between the transmission and the differential housing. 2. Remove the PTO clutch assembly. 3. Remove the emergency brake from the transmission. 4. If installed, remove the transmission hand brake shield from the pinion drive gear. 5. Remove the differential and the differential lock assembly. 6. Remove the bolts and washers that secure the drive pinion. 7. Remove the drive pinion assembly (1) from the housing (3). Facilitate removal by placing jacking bolts (4) in the holes in the bearing retainer (2).

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Next operation: Differential - Disassemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Disassemble - Drive pinion Prior operation: Differential - Remove (27.106) 1. Remove the staked nut or the double nut, if installed, from the pinion axle. 2. Remove the spacer, gear, and emergency brake shims from the transmission, if it is assembled, or the washer from the pinion axle. 3. With a nylon hammer, tap the end of the pinion axle by the gear retainer. 4. Remove the block ring from the front part of the pinion and remove the pinion axle gearing using a puller with a suitable attachment. 5. Remove taper and roller from the axle using a puller with a suitable attachment. Next operation: Differential - Inspect (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Inspect - Drive pinion Prior operation: Differential - Disassemble (27.106) 1. Clean and inspect all components for damage or excessive wear. Replace as needed. 2. If necessary, remove the gearing cups from the retainer using the sliding hammer with a suitable attachment. To install the gearing cups, use a step plate and the press. 3. Install the rear taper and roller in the pinion axle using a puller with a suitable attachment and a bushing. Next operation: Differential - Assemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Assemble - Drive pinion Prior operation: Differential - Inspect (27.106) NOTE: Installation of a new pinion shaft requires the installation of a new, matching ring gear. Assemble the drive pinion in the reverse order of disassembly, with this requirement: 1. Check and adjust the pinion bearing preload. Refer to Differential - Preload - Drive pinion bearing (27.106). Next operation: Differential - Install (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Install - Drive pinion Prior operation: Differential - Assemble (27.106) Install the drive pinion in the reverse order of removal, with this requirement: 1. Tighten the bearing retainer support screws to a torque of 136 - 170 NÂˇm (100 - 125 lb ft). Next operation: Differential - Preload (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential - Preload - Drive pinion bearing Prior operation: Differential - Install (27.106) Before installing the final drive pinion and the retainer, check the preload of the pinion bearing: 1. Lubricate the pinion bearing and place the retaining pinion in a bench screw. 2. Install the staked nut or the double nut, the new washer and the locknut.

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3. With the gauge (1) and the adaptor (2) of the drive pin preload tool or with a spring scale, check and adjust the preload. • Drive pin preload tool: 1.1 - 1.9 N·m (0.8 - 1.4 lb ft) • Spring scale: 5.9 - 10.5 kgf (13.01 - 23.15 lbf)

4. Once the correct preload has been set, tighten the locknut and fold the washer's flaps or stake the nut accordingly. 5. Check the preload again.

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Disassemble Prior operation: Differential lock hydraulic control - Prepare (27.106) 1. Refer to the Differential lock hydraulic control - Exploded view (27.106) for an overview of the differential lock components. 2. Remove the cotter pin and washer (1) from the pedal assembly (2). Remove the guide bracket (3).

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3. Remove both bolts (1) from the hanger and lock rod assembly (2).

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Rear axle system - Rear bevel gear set and differential

4. Remove the grooved pin from the rod assembly. Remove and disassemble the hanger and lock rod assembly. 5. Turn the pedal assembly 90 Â° away from the tractor and slide the pedal out of the slot opening on the operator platform.

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6. If the differential shifter fork needs to be replaced, remove the left axle housing to obtain access. Refer to Rear axle - Remove (27.100) and Rear axle - Disassemble (27.100). 7. With the axle housing taken out, remove the two bolts (1) that fix the pivot shaft (2) to the differential box. Remove the pivot shaft and shifter fork (3) together, as one piece.

Next operation: Differential lock hydraulic control - Inspect (27.106) Differential lock hydraulic control - Assemble (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Assemble Prior operation: Differential lock hydraulic control - Disassemble (27.106) Assemble the differential lock command linkage in the reverse order of disassembly, with the following requirements: 1. Inspect all components and replace warn or damaged parts. 2. Tighten the pivot axle bolts in the differential lock fork to a torque of 57 - 76 N·m (42 - 56 lb ft). 3. Tighten the pedal guide bolt hardware to a torque of 57 - 76 N·m (42 - 56 lb ft). 4. If the differential housing was removed, ensure the bolts are tightened to a torque of 176 - 258 N·m (130 190 lb ft). 5. Refill the axle with the correct grade and quantity of oil. Next operation: Differential lock hydraulic control - Adjust (27.106)

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Adjust Prior operation: Differential lock hydraulic control - Assemble (27.106) 1. If the differential lock control linkage has been disassembled for service, connect the lower rod to the upper rod with the threaded coupler (1), simultaneously threading the coupler onto the upper and lower rods. Adjust as required.

20118331

20118333

2. If the differential lock has not been disassembled and only requires adjustment, loosen the jam nuts (1) and adjust the pedal free play using the threaded coupler.

3. Adjust the coupler (as shown) to provide a minimum of 6 mm (0.25 in) free play at the differential lock pedal.

NOTE: : A minimum of 6 mm (0.25 in) of free play will ensure that the differential lock will fully disengage.

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Rear axle system - Rear bevel gear set and differential

WARNING Hazard to bystanders! Make sure the area surrounding the machine is clear of all persons before starting the engine. Failure to comply could result in death or serious injury. W0090A

After adjusting the free play, depress the pedal and tighten the two jam nuts to 87 - 116 NÂˇm (64 - 86 lb ft).

20118331

NOTE: After tightening the jam nuts, test the differential lock by starting the tractor and engaging and disengaging the differential lock. After testing the differential lock, recheck the differential lock pedal free play. If the specification of a minimum of 6 mm (0.25 in) is not met, repeat the adjustment procedure until the specification is achieved.

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Disassemble Dismounting 1. Loosen the pedal pressure nut and disassemble the pedal. 2. Remove the two bolts that fix the differential box support and remove the support with the connecting rods as an assembly. 3. Remove the fork rods from the differential housing. 4. Dismount the sealant of the box operation connecting rod if there are leaks or damage. 5. If the fork has to be replaced, the housing on the left side shaft has to be disassembled as described in section Rear axle - Remove (27.100). 6. With the housing dismounted, remove the two bolts that fix the pivot shaft of the fork to the differential box and dismount the shaft and fork as an assembly. 7. Dismount the fixation segment and washer and next, remove the fork pivot shaft.

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Rear axle system - Rear bevel gear set and differential

Differential lock hydraulic control - Inspect Checking and Repairing 1. Clean and inspect all components for damage or excessive wear. Replace the new components as necessary. 2. If the pedal support bushings have to be replaced, proceed as follows: A. Dismount the support pin and pedal, next separate the pedal from the support. B. With the bushing assembly, tool No. 818 , remove and install the two support bushings . C. Align the pedal with the support and install the pin.

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Rear axle system - Rear bevel gear set and differential

Differential lock - Troubleshooting Problem Possible Cause The differential lock does Outer linkage is damaged or broken not work Inside linkage, transverse axle, fork or pivot axle are damaged or broken Lock adaptor teeth or coupling is damaged The differential lock does Broken spring between adaptor and coupling not disconnect Adaptor teeth or coupling is damaged or peeling

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Correction Change or repair damaged parts Remove cover and inspect Remove and inspect differential lock Remove differential and change spring Remove differential and change damaged parts

Index Rear axle system - 27 Rear bevel gear set and differential - 106 Differential - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Differential - Assemble - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Differential - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Differential - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Differential - Disassemble - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Differential - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Differential - Exploded view - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Differential - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Differential - Inspect - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Differential - Install - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Differential - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Differential - Preload - Drive pinion bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Differential - Remove - Drive pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Differential lock - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Differential lock - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Differential lock hydraulic control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Differential lock hydraulic control - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Differential lock hydraulic control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Differential lock hydraulic control - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Differential lock hydraulic control - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Differential lock hydraulic control - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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Rear axle system - 27 Planetary and final drives - 120

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Rear axle system - 27 Planetary and final drives - 120

FUNCTIONAL DATA Planetary final drive Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Planetary final drive Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Rear axle system - Planetary and final drives

Planetary final drive - Overview In order to increase the torque transmitted to the rear wheels, there is a set of epicyclic reduction gears is in each rear axle housing. The end of each intermediate shaft functions as a planetary sun gear around which there are three side gears. The side gears are mounted onto a support that is splined to the rear axle. The side gears mesh with a ring gear that is mounted on the axle housing. When the intermediate shaft turns, the side gears turn around the inside of the fixed ring gear. This action makes the planetary sun gear turn and reduces the speed, which transmits more torque to the rear axle and wheels.

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Rear axle system - Planetary and final drives

Planetary final drive - Disassemble Prior operation: Rear axle - Disassemble (27.100) 1. Remove the ring that holds the planetary (side) gear shafts. 2. Place the carrier assembly on a press. NOTE: The cone and bearing assembly is only installed on the carrier of model 8 x 2 tractors. 3. Remove the cone and roller assembly (5) and the planet gear shafts (3) using a step plate (1), three sockets (2), a bearing puller attachment (4), a taped base (6) and a slave ring (7).

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RCPH09TTS410AAD

4. Remove the support gears (3), thrust washers (2) and spacers from the carrier (5). Retain the rollers (4) located between the planet gear shafts (1) and the gears for reassembly.

5. Use the sliding hammer and a puller to remove the gear funnel situated inside the axle housing.

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Rear axle system - Planetary and final drives

Planetary final drive - Visual inspection CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Planetary final drive - Disassemble (27.120) 1. Clean and inspect all components for damage or excessive wear. Replace as required. 2. If the planetary ring gear requires replacement: A. Insert the planetary crown puller/inserter (2) behind the ring gear (1) and adjust the moveable plates to desired location. Tighten the locknuts (3). B. If needed, manufacture a special plate for use with the planetary crown puller/inserter as shown. C. Position the axle housing under a hydraulic press with the ball end of the housing downward. Insert a bar between the planetary crown puller/inserter and the press ram. Press the ring gear out. D. Install a new ring gear with the bell end of the axle housing up. Press the ring gear in, until completely seated and no gap exists between bottom of the gear and the housing shoulder.

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Rear axle system - Planetary and final drives

RCPH09TTS001FAF

(A) 254.0 mm (10.0 in) (B) 76.2 mm (3.0 in) (C) 45 Â° (D) 60 Â° (E) 63.5 mm (2.5 in) (F) Radius = 127.0 mm (5.0 in) (G) 4 x 12.7 mm (0.5 in) in B.S.W. (H) 101.6 mm (4.0 in) (I) 12.7 mm (0.5 in) Next operation: Planetary final drive - Assemble (27.120)

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Rear axle system - Planetary and final drives

Planetary final drive - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Planetary final drive - Disassemble (27.120) Prior operation: Planetary final drive - Visual inspection (27.120) Assemble the planetary gear assembly is the reverse order of disassembly, Planetary final drive - Disassemble (27.120), with these requirements: 1. When assembling the planetary support, install the same number of rollers to both sides of the spacer between the gear housing. 2. Hold rollers with grease while simultaneously installing the side gear axles. Place the shafts, with the flat part at the head isolated in the center of the support, and then install the fastening ring (1). Fold the ends (2) to set the fastening ring in place.

RCPH09TTS413AAD

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Index Rear axle system - 27 Planetary and final drives - 120 Planetary final drive - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Planetary final drive - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Planetary final drive - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Planetary final drive - Visual inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124

FUNCTIONAL DATA Axle shaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Rear axle system - Final drive hub, steering knuckles, and shafts

Axle shaft - Exploded view Standard halfshaft

RCPH09TTS002GAF

1. 2. 3. 4. 5.

Gears and planet reduction support Screw and support holding retainer Inner brake housing Brake discs and actuator assembly Outer brake housing

6. Planetary gear and axle 7. Wheel shaft 8. Rear axle housing 9. Bearing 10. Shim

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Index Rear axle system - 27 Final drive hub, steering knuckles, and shafts - 124 Axle shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Power Take-Off (PTO)

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Power Take-Off (PTO) - 31

[31.101] Rear mechanical control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 [31.220] Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4

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7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Power Take-Off (PTO) - 31 Rear mechanical control - 101

FUNCTIONAL DATA Rear mechanical control Logical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Power Take-Off (PTO) - Rear mechanical control

Rear mechanical control - Logical diagram PTO does not operate correctly • Is the low pressure warning light on? • Check the low pressure and steering pump circuit pressure and flow rate. • Has the damage been identified? • Is the low pressure circuit feed tube well connected? • Assemble the line correctly • The PTO operates, but with insufficient power to operate the equipment. • Connect a dynamometer to the PTO, adjust engine speed to 1500 r.p.m. and the dynamometer to maximum load. • Does the engine stop? • Check the power required by the implement • Is the PTO lever link to the command valve connected? • Remove the valve and check the whether the spool is not stuck to the valve carcass. • Is the alternator powered? • Did the fuse melt? • Check the electric harness for an open circuit.

The PTO shaft rotates constantly. • The PTO shaft rotates continuously when it is disengaged/turned off • If the feeder tube to the low pressure circuit is fitted correctly and the PTO activation control is damaged, examine the brake belt and the PTO piston. • If the PTO articulation from the selection lever to the control valve is connected, remove the valve and check if the spool is stuck

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Index Power Take-Off (PTO) - 31 Rear mechanical control - 101 Rear mechanical control - Logical diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

TECHNICAL DATA Rear electro-hydraulic control Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Rear electro-hydraulic control Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear electro-hydraulic control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Take-Off (PTO) control valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE Power Take-Off (PTO) control valve Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Take-Off (PTO) control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Torque Torque values Item Rear shaft roller bearing retainer bolts PTO outlet shaft bearing retainer PTO valve adjuster Front pin Tighten rear (clearance 1/4 of a turn) Rear pin pressure nut PTO break belt adjustment bolt Clutch housing bolts Deposit cap bolts Fork bolts

Kgf/m 6.5 - 8.5 kgf/m 19.0 - 23.0 kgf/m

Nm 65 - 85 N·m 190 - 230 N·m

27 - 35 kgf/m 0.1 kgf/m 2.1 - 2.7 kgf/m 0.1 - 0.12 kgf/m 1.9 - 2.3 kgf/m 3.7 - 5.0 kgf/m 2.7 - 3.4 kgf/m

27 - 35 N·m 1.0 N·m 21 - 27 N·m 1 - 1.2 N·m 19 - 23 N·m 37 - 50 N·m 27 - 34 N·m

Sealing Thread seal NEW HOLLAND, part number 82995773.

Rear electro-hydraulic control - General specification Electric hydraulic power take-off Specifications Solenoid operated PTO with fixed displacement hydraulic pump Pressure regulator valve Engine @ 2100 RPM 16 - 18 bar Engine @ 800 RPM engine 13 barminimum Lubrication circuit regulator valve @ 800 RPM engine 5.3 - 8.5 bar

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Mechanical schema

LAIL11TS0490F0A

540 RPM mechanical PTO mechanical schematic 1. 2. 3. 4. 5. 6.

PTO Outlet Shaft Cover Output axle Driven Gear Oil filling tube PTO valve assembly Hydraulic pump intermediate gear

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

Input Axle Hydraulic Pump Drive Gear PTO clutch Brake belt Rear shaft PTO drive gear

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description Description and mechanical operation The power take-off (P.T.O) transfers engine power directly to mounted or trailed equipment through a splined shaft (1) at the rear of the tractor, Fig 1. The P.T.O. assembly of the Series 30 tractors is constituted of a mechanical system and a hydraulic system. *The mechanical system is composed of gears, shafts and clutch. Its function is to transfer the power from the engine flywheel to the output shaft. *The hydraulic system activates the P.T.O. clutch disks, either allowing the power to reach the output shaft, or not. In the Series 30 tractors, the hydraulic drive of the P.T.O. clutch is mechanical, by means of a lever. The standard P.T.O. output shaft has 6 splines and turns at 540 RPM when the engine speed is 1935 RPM. Fig. Rear electro-hydraulic control - Mechanical schema (31.104) shows the engine power pathway to the output shaft. The input shaft (7) transmits the power from the engine flywheel up to the P.T.O. clutch, passing through the primary and secondary top transmission shafts. The rear shaft is splined in the clutch and transmits the power to the output shaft gears. When the P.T.O. is on, the steel friction disks (sinterized) of the clutch assembly are compressed by the piston that is activated by the oil pressure of the low pressure hydraulic circuit. NOTE: The P.T.O. output shaft speed is related to the engine speed, irrespective of the gear engaged in the transmission and the tractor speed.

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LAIL11TS0100A0A

Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Overview Electric-Hydraulic PTO – Mechanical Operation The mechanical operating principle for the electric-hydraulic PTO is basically the same as the mechanical PTO principle and we can take the latter as a basis to understand the operation. The path followed by the engine flywheel power to the output shaft is the same, except for the activation mechanism (on and off), which is not mechanical (lever), but electric (switch). The output shaft working speed depends on the engine speed. By design, the shaft with six thick splines is indicated for normal work at 540 RPM. The shaft with 21 thin splines is aimed at more heavy duty work that consequently requires more power. The TS series electric-hydraulic PTO system types available fit into these two categories: • One speed PTO with one standard output shaft with six splines to work at 540 RPM. • Non-variable two speed PTO with two output shafts with variable six and 21 spline output shafts to work at 540 RPM and 1000 RPM.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Overview One speed PTO Figure Rear electro-hydraulic control - Overview (31.104) shows a simplified form of the drive line from the engine to the output shaft. The PTO input shaft passes through the top transmission shafts and is splined at both ends, the engine flywheel and the PTO clutch hubs. The rear PTO shaft is splined into the PTO clutch and transmits the drive to the output shaft gear. When the PTO is engaged the clutch set friction and steel disks are pressed against one another by the hydraulic clutch piston to transmit the drive from the flywheel to the PTO output shaft. The output shaft speed is independent from the transmission and the tractor forward speed, it is directly related to the engine speed. The PTO clutch for the one speed PTO systems may be engaged either mechanically or by electric solenoid. When servicing the clutch, the appropriate operation and service sections in this chapter should be consulted.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Exploded view Rear electro-hydraulic control - Overview (31.104): Mechanical schematic of PTO mechanics: 540 RPM 1.

Upper shaft

Drive gear

Ring gear bearing

Bearing cover and retainer

Bearing retainer

Thin shim

Thick shim

Sleeve

PTO output shaft

10. Output shaft lock ring 11. Bearing 12. Covers 13. 540 RPM driven gear 14. Output shaft front needle bearing

LAIL11TS0301B0A

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Overview Two non-variable speeds PTO For tractors equipped with two non-variable speeds PTO, rear shaft PTO drive is also transferred by means of the multiple gear and/or the 540 RPM or 1000 RPM gear to the output shaft. When the 6-spline PTO shaft is fitted, the shaft splines engage in the 540 RPM, Power Take-Off (PTO) clutch Overhaul (31.114) gears. This output shaft will now turn at 540 RPM when the engine is run at 2890 RPM. When the 21-spline shaft is assembled, the splines on it engage with the 1000 RPM gear, allowing the output shaft to rotate at 1000 RPM when the engine speed is adjusted to 2050 RPM. NOTE: The PTO shafts used for variable PTO systems can not be assembled on tractors with a non-variable system.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Exploded view Two non-variable speed PTO components: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Drive gear Drive gear bearing shims Bearing retainer 540 RPM driven gear driven gear 1000 RPM Output shaft brake Output axle Sleeve Bronze rings Covers Needle bearing Output shaft front bearing Upper shaft Locking ring

LAIL11TS0302B0A

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Dynamic description Disengagement of the control valve and clutch from the PTO â&#x20AC;&#x201D; description and operation The PTO, with mechanically operated clutch and control valves, is engaged with a selection lever located on the left hand side of the operator seat, Fig. 1. When the lever is activated, the PTO control valve spindle can assume the engaged or disengaged position.

LAIL11TS0101A0A

PTO feeder clutch disengagement Refer to fig. 2 . The return oil of the steering circuit goes through the pump and on to the PTO control valve. In the PTO clutch assembly, the low-pressure circuit's oil pressure is regulated by the pressure regulator valve in the low-pressure circuit. This valve regulates the pressure of the entire low-pressure circuit (steering return oil). The excess pressure is discharged to the lubrication circuit. The low pressure hydraulic circuit drives the PTO and Dual Power clutch (when installed). The steering return hydraulic circuit must have a pressure of 15 - 18 bar. Consult Hydraulic systems - Detailed view (35.000), for the description and working of the low pressure hydraulic circuits. The excess oil pressure that passes through the pressure regulating valve provides the PTO and Dual Power clutches with lubrication. The oil pressure in the lubrication circuit is regulated by a valve located in the PTO control valve body, together with the low-pressure circuit pressure regulating valve. The pressure in the lubrication circuit must be between 5.0 - 8.0 bar. Under normal working conditions and with hot oil, this valve is normally closed. When the PTO selector lever is in the disengaged position, the control valve spindle directs the oil pressure to the brake piston and allows the clutch piston drive oil to return to the tank by the action of the piston return spring. The hydraulic pressure displaces the brake piston against the return spring resistance, fastens the belt and prevents the clutch housing from continuing to turn by drag. When the tractor engine is switched off, the pressure regulator valve closes and a groove in the valve spindle body allows the oil applied to the brake piston to return to the tank. This facilitates coupling the implements to the PTO output shaft.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Oil flow in PTO mechanical â&#x20AC;&#x201D; clutch disengagement

LAIL11TS0004G0A

Oil pressure 1. Clutch housing 2. Sealing rings 3. Connection clutch 4. Orifice 5. Lubrication circuit valve 6. Low-pressure circuit pressure regulation valve

Lubrication 7. Oil outlet for the radiator 8. Restriction 9. Control valve spindle 10. Stop and ball spring 11. Brake piston 12. Brake piston return spring

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13. 14. 15. 16. 17.

Return (Tank) Clutch piston return spring Clutch hub Clutch discs Brake belt Clutch piston

Power Take-Off (PTO) - Rear electro-hydraulic control

LAIL11TS0102A0A

PTO feeder clutch disengagement "A" Brake applied — Clutch loose Loose brake "B" — Loose clutch Loose brake "C" — Loaded clutch Loose brake "D" — Engaged clutch Oil pressure 1. Pressure sensor perforation 2. Pressure Regulator Valve 3. Restriction

Lubrication 4. Clutch and spring for the control valve; 5. Stop and ball spring

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Return (Tank)

Power Take-Off (PTO) - Rear electro-hydraulic control

PTO feeder clutch disengagement Refer to fig. 3 and 4. The control valve spool is composed of two parts connected by a connecting rod and a spring, which allows the clutch to engage smoothly. When the PTO selector lever starts to move into the engaged position, the control valve blocks the oil pressure line and allows the oil pressure in the clutch brake to return to the tank (rear axle). This way one produces a "loose brake" and "loose clutch" situation, Fig. 3 "B" (Loose brake â&#x20AC;&#x201D; loose clutch). As the selector valve is moved into the engaged position, the control valve spindle discovers the opening, and a controlled flow of oil flows to the clutch. At the same time, the oil passes through a perforation and reaches the end of the control valve. This way one produces a "loose brake" and "loaded clutch" situation, Fig. 3 "B" (Loose brake â&#x20AC;&#x201D; loaded clutch). The increase in pressure in the clutch and in the extremity of the control valve spool displaces the spool against the pressure of the spring that is located between the two halves of the control valve, and which restricts the flow of oil to the clutch. This restriction of oil ensures that the PTO engagement is cushioned in relation to the movement of the selector lever. When the selector lever is in the completely engaged position, the spring at the end of the control valve spool is completely compressed and the spool completely releases the passage of oil to the clutch. It is no longer possible to dampen against the compressed spring and maximum pressure is applied to fully engage the clutch, Fig. 4. If the selection lever is moved quickly to the engaged position, a restriction at the pressure line input (item (8), Fig. 4) reduces the oil flow to the clutch and prevents the engagement from occurring abruptly.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Oil flow in PTO mechanical â&#x20AC;&#x201D; clutch engaged

LAIL11TS0005G0A

Oil pressure 1. Clutch housing 2. Sealing rings 3. Clutch carrier 4. Orifice 5. Lubrication circuit valve 6. Low-pressure circuit pressure regulation

Lubrication 7. Oil outlet for the radiator 8. Restriction 9. Control valve spindle 10. Stop and ball spring 11. Brake piston 12. Brake piston return spring

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13. 14. 15. 16. 17.

Return (Tank) Clutch piston return spring Clutch hub Clutch discs Brake belt Clutch piston

Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Exploded view P.T.O. control valve and clutch brake components

LAIL11TS0004F0A

Cotter pin

Spring

Control valve spindle

Control valve body

Brake piston

Return spring

Lock ring

Guide

Cover (chamfer facing spring)

10. Lock ring 11. Lubrication circuit safety valve 12. Low pressure circuit pressure regulation valve 13. Ball and stop spring

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Assemble Assembly Assembly is done in the reverse order to the disassembly procedure. 1. Install the pressure regulator valve spool of the low pressure circuit with the groove facing in, that is, on the opposite side of the valve spring. 2. Keep the brake belt submerged in the rear axle oil for at least 3 min before installing it. 3. Adjust the brake belt as follows:Loosen the cotter nut (1) and screw on the adjuster (2) to tighten the brake belt to a torque of 0.1 - 0.12 kgf/m, Fig. 1. Loosen the adjuster screw two half turns and fasten the cotter nut. To check the concentricity of the brake belt after adjustment, proceed as follows: * Maintain the control valve case in the 3 h position. The control valve housing should fall into the 6 h position by its own weight. Fold the belt a little to give it shape, as necessary, and repeat the adjustment. LAIL11TS0113A0A

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Inspect Inspection and repairs 1. Check all the components for wear and damage and replace them as necessary. 2. Replace all sealing rings.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) control valve - Install Assembly is done in reverse order from disassembly. If the PTO brake belt is to be replaced, soak it in rear axle oil for at least 3 min before assembling.

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Index Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104 Power Take-Off (PTO) control valve - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Power Take-Off (PTO) control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Take-Off (PTO) control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Power Take-Off (PTO) control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Take-Off (PTO) control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Rear electro-hydraulic control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear electro-hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear electro-hydraulic control - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Rear electro-hydraulic control - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rear electro-hydraulic control - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Rear electro-hydraulic control - Mechanical schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear electro-hydraulic control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear electro-hydraulic control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Rear electro-hydraulic control - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TECHNICAL DATA Front drive shaft Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gears - Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Front drive shaft Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Power Take-Off (PTO) clutch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Front drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Driven shaft Fork and shift rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Power Take-Off (PTO) clutch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Power Take-Off (PTO) clutch brake - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Shimming Longitudinal play in rear axle Longitudinal play Shim size

0.46 - 1.0 mm 0.25 mm

Front drive shaft Gears - Shimming Drive gear longitudinal clearance (2 speed PTO systems) Longitudinal clearance Shim sizes

0.13 mm 0.025 mm; 0.076 mm; 0.127 mm; 0.305 mm; 0.508 mm

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Exploded view Two speed PTO upper shaft components

LAIL11TS0480F0A

1. 2. 3. 4. 5.

Bearing retainer Shims (driven gear longitudinal clearance) Drive gear set Shims (rear shaft longitudinal clearance) Upper shaft

6. 7. 8. 9.

Lock Ring Lock Ring Bearing Bearing

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two non-variable speed PTO driven output shaft and gears

LAIL11TS0694F0A

1. 2. 3. 4. 5. 6. 7. 8.

Output shaft lock ring Output shaft guard Output axle retainer Join Output shaft sleeve retainer Output shaft sleeve Separating rings 540 RPM driven gear

9. 10. 11. 12. 13. 14. 15. 16.

Thin separating ring Thick separator ring Output shaft front bearing Needle bearing 1000 RPM driven gear Output shaft rear bearing Locking ring PTO output shaft

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Overview P.T.O. clutch and valve assembly

LAIL11TS0107A0A

1.Brake belt 2.P.T.O.clutch housing 3.Clutch support 4.Valve assembly 5.Pressure regulating valve 6.Control valve stop 7.Lubrication circuit safety valve 35777183

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Exploded view Clutch and disk housing

LAIL11TS0683F0A

1. 2. 3.

Clutch housing Sinterized disks with internal splines (5 units) Pressure disk

4. 5.

Locking ring Steel disks with external splines (5 units)

1. With a spring compressor FT 4101 or FNH 01312 and a suitable press, remove the piston and the return spring, Fig. 2. Clutch and valve assembly: 1. 2. 3. 4. 5. 6.

Clutch housing Piston Spring retainer Brake Return Spring Internal piston sealant LAIL11TS0632A0A

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

2. Examine the cast iron rings in the clutch housing. Replace if worn or damaged (1), 3 units, Fig. 3.

LAIL11TS0633A0A

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Remove Axles and gears (two-speed PTO) Dismounting 1. Drain the rear shaft/transmission oil. 2. Remove the rear axle bearing retainer (4), Fig. 1 . PTO rear shaft bearing retainer: 1.

Multiple clutch

Rear shaft box

Bearing cup

Retainer

Sealant LAIL11TS0404A0A

LAIL11TS0405A0A

LAIL11TS0406A0A

3. Remove the multiple gear (2), Fig. 2. 4. Remove the shims (4) from the rear axle (3) and pull the tractor shaft, Fig. 3. 5. Remove the rear shaft set lower cover. Disassembling the multiple gear: 1.

Bevel bearing

Multiple clutch

Bevel bearing

6. Remove the PTO output shaft. 7. Hold the driven gears and remove the output shaft sleeve and bearing set. See Figure Front drive shaft - Exploded view (31.114) . Disassemble the driven gears and the thrust rings. 8. Disassemble the output shaft front bearing. Disassembling the rear PTO shaft: 1.

PTO clutch housing

Brake

Rear shaft

Shims

Brake

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Check Inspection Refer to Figure Front drive shaft - Exploded view (31.114). Check the components for wear and damage and replace them as necessary. Replace all the ‘O’ segments, oil seals and gasket.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - Install Assembly 1. Installing the two non-variable speeds PTO shaft. 2. For assembly, invert the disassembly procedure. 3. Install with reference to Figure 1 . 4. If the upper shaft, drive gear bearings, rear bearing retainer or rear shaft central housing need replacement, the following adjustments need to be done. Two non-variable speeds PTO components: 1. Drive gear 2. Shims (drive gear longitudinal clearance) 3. Bearing retainer 4. 540 RPM driven gear 5. 1000 RPM driven gear 6. Output shaft brake 7. Output axle 8. Sleeve 9. Bronze separator rings 10. Covers 11. Needle bearing 12. Output shaft front bearing 13. Upper shaft LAIL11TS0302B0A

14. Locking ring

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - End play Drive gear longitudinal clearance 1. Place the drive gear set in the central housing. 2. Assemble approximately 2.0 mm from the shims behind the rear bearing cup. DO NOT assemble the "O" segment. 3. Place the bearing retainer (1) with the word â&#x20AC;&#x2DC;TOPâ&#x20AC;&#x2122; facing upward and tighten the bolts enough to ensure the bearings are seated. 4. Measure the clearance at several distinct points to determine the average clearance, Fig. 1.

LAIL11TS0625A0A

Calculate the required shim thicknesses: Shim thicknesses Average clearance (subtract) Longitudinal clearance

2.03 mm 0.36 mm 1.67 mm 0.10 mm 1.57 mm

Correct shim thicknesses: 1.57 mm. 5. Assemble the shims behind the bearing cup. 6. Assemble the rear shaft shim(s) that was removed during disassembly. 7. Assemble the bearing retainer using the new "O" segment.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Front drive shaft - End play Adjusting longitudinal rear shaft clearance 1. With feeler gauges (1) check the longitudinal clearance in the upper shaft (2), Fig. 1. 2. Remove or add shims (14), Front drive shaft - Install (31.114), between the rear brake and the front bearing to give longitudinal clearance of 0.46 - 1.0 mm.

LAIL11TS0407A0A

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Driven shaft Fork and shift rail - Install Assembly NOTE: Incorrect assembly of the clutch wears out the body, produces leaks and requires repairing after a few hours of operation.

LAIL11TS0225A0A

5. Make sure the clutch can rotate freely.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Remove PTO control valve and clutch Remove 1. Remove the hydraulic cover to expose the PTO clutch (1) and valve (3), Fig. 1. 2. Remove the PTO rear axle bearing retainer (1) and remove the axle, bearing and drive gear (2), Fig. 2. 3. Remove the banjo bolt from the radiator tube (1) and the two fixation pins (2) and (3), Fig. 3. 4. Remove the plastic transfer tube from the inlet orifice of the oil radiator. 5. Loosen the inlet tube retention clip (2), Fig. 1 . 6. Slide the PTO clutch backwards and disengage the articulation to the control valve.

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LAIL11TS0103A0A

LAIL11TS0104A0A

LAIL11TS0105A0A

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Install Installation The installation is done in the reverse order to that used for removal. During installation fasten the fixation pins as follows, Fig. 1:

LAIL11TS0114A0A

1. Install the front pin (3) and fasten to 2.7 - 3.5 Kgf/m. 2. Install the back pin (2) and fasten to 0.1 Kgf/m. 3. Loosen the back pin 1/4 turn and fasten the counter-nut to 2.1 - 2.7 Kgf/m. 4. Check whether clutch is free to turn. Fig. 1 : P.T.O. control valve retainers: (1). Banjo bolt of the oil radiator tube, (2). Rear fixation pin and counter-nut, (3). Front fixation pin

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Disassemble

LAIL11TS0107A0A

Dismounting 1. Remove the hub and the shim, PTO clutch and Hub Assembly: (1). Clutch (2). Hub (3). Shim

LAIL11TS0108A0A

LAIL11TS0109A0A

LAIL11TS0110A0A

2. Slide the gear from the clutch support. Remove the brake and disassemble the clutch assembly. Clutch housing and drive disks, (1). Clutch housing (2). Damper spring (6). Steel disks with external grooves (3)bolt. Friction disks with internal grooves (5)bolt. Pressure plate (4)bolt. Brake

3. With spring compressor FT 4101 or FNH 01312 and a suitable press, remove the piston and the return spring. Clutch and valve assembly: (1)bolt. Clutch housing (2)bolt. Piston (6)bolt. Piston seals (5)bolt. Return spring (3)bolt. Spring retainer (4)bolt. Locking ring

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

4. Check the seal rings in the clutch housing (1). Replace them if damaged or worn.

LAIL11TS0111A0A

LAIL11TS0112A0A

5. Remove the belt assembly from the clutch brake. 6. Separate the clutch support from the control valve assembly. Control valve and belt brake for PTO: (1)bolt. Pressure regulating valve (7)bolt. Lubrication circuit discharge valve (2)bolt. Brake cylinder (3)bolt. PTO control valve. (4)bolt. Brake belt fixing pin (6)bolt. Brake belt (5)bolt. Clutch carrier

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch - Overhaul Clutch - service 1. Remove the hydraulic cover to expose the PTO clutch and valve set. PTO clutch and valve assembly: 1.

Clutch hub

Rear shaft

Valve body

Support

LAIL11TS0344A0A

LAIL11TS0345A0A

LAIL11TS0699A0A

LAIL11TS0347A0A

2. Remove the rear axle bearing retainer. PTO rear shaft bearing retainer: 1.

Multiple clutch

Rear shaft box

Bearing cup

Retainer

Sealant

3. Remove the multiple gear. Disassembling the multiple gear: 1.

Bevel bearing

Multiple clutch

Bevel bearing

4. Remove the shims from the rear axle and pull the tractor shaft. Disassembling the rear PTO shaft: 1.

PTO clutch housing

Brake

Rear shaft

Shims

Brake

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. PTO clutch oil supply tube. 1.

Segment 'O'

Supply tube

Retention Clip

LAIL11TS0348A0A

LAIL11TS0349A0A

LAIL11TS0350A0A

LAIL11TS0700A0A

6. Remove the PTO retainers and the banjo bolt on the outside of the transmission box. PTO control valve retainers: 1.

Plastic transfer tube

Banjo bolt

Rear retainer/adjusting pin

Front retaining pin

Lubricating oil tube

NOTE: Tighten the clutch by hand to remove the retainers, securing the PTO assembly to remove the fixing pins.

7. Remove the PTO clutch set, valve and hub. PTO clutch and valve set: 1.

Brake belt

Clutch carrier

Solenoid

Valve body

Clutch housing

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

8. Identify the type of PTO clutch and valve set fitted. PTO clutch and valve set: 1.

Solenoid

Valve body

Clutch kit A* Lubrication circuit regulator valve. B* Low pressure regulator valve. * Only tractors fitted with fixed debit gear pumps.

NOTE: DO NOT assemble the incorrect type of PTO valve on the tractor. LAIL11TS0352A0A

9. Remove the hub and retract the impulse washer. 10. Slide the clutch from the clutch support. PTO clutch and valve set: 1.

Clutch

Hub

Impulse Washer

LAIL11TS0353A0A

11. Disassemble the brake and remove the clutch disks, Power Take-Off (PTO) clutch - Exploded view (31.114).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Tension adjust Adjust the brake belt as follows: • Loosen the cotter nut (1). • Screw in the adjuster (2), see Fig. 1, to tighten the brake belt until the bolt is tightened to 1 - 1.2 N·m. • Loosen the adjusting bolt 2 1/2 turns and tighten the cotter nut. • To check the brake belt concentricity after adjustment, hold the PTO clutch and brake set as indicated in Fig. 1. • Position the control valve housing at 3 o'clock. The control valve housing should fall into the 6 o'clock position under its own weight. NOTE: Both the PTO clutch brake belt adjustment and the recommendations are the same as those for the mechanical PTO clutch. Control valve and solenoid components 1. 2. 3. 4.

Valve body Control valve Pilot valve Solenoid coil

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LAIL11TS0634A0A

Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Driven shaft Fork and shift rail - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front drive shaft - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front drive shaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front drive shaft - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Front drive shaft - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Front drive shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Front drive shaft - Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Front drive shaft Gears - Shimming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Power Take-Off (PTO) clutch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power Take-Off (PTO) clutch - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Power Take-Off (PTO) clutch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Power Take-Off (PTO) clutch - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Take-Off (PTO) clutch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Power Take-Off (PTO) clutch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Power Take-Off (PTO) clutch brake - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

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Power Take-Off (PTO) - 31 Gearbox - 220

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Power Take-Off (PTO) - 31 Gearbox - 220

SERVICE Gearbox Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Power Take-Off (PTO) - Gearbox

Gearbox - Disassemble Disassembly 1. Drain the rear axle oil from the rear axle tank. 2. Remove the P.T.O. rear axle assembly, Fig. 1. PTO Rear axle and bearing retainer: (1) P.T.O. bearing retainer (2) Rear axle, gear and bearing 3. Remove the draw bar (if installed); engage automatic and then remove the sump cover.

LAIL11TS0115A0A

LAIL11TS0003B0A

4. Remove the roller bearing retainer (5) from the P.T.O. (Fig. 2). 5. Support the driven gear, remove the P.T.O. output shaft and dismount the gear, shims and bearing. 6. Remove the front bearing, item (11) from the transmission housing. Installing the P.T.O. one speed shaft: (1) Upper shaft (2) Drive gear (3) Drive gear bearing (4) Bearing cover and retainer (5) Bearing retainer (6) Thin shim (7) Thick shim (8) Sleeve (9) P.T.O. output shaft (10) Output shaft lock ring (11) Bearing (12) Cover (13) 540 RPM driven gear (14) Output shaft front needle bearing

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Power Take-Off (PTO) - Gearbox

Gearbox - Inspect Inspection 1. Check all the components for damage and replace them as necessary. 2. Replace the seal rings and joints.

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Power Take-Off (PTO) - Gearbox

Gearbox - Assemble Assembly Assembly is done in the reverse order to that used for dismounting. 1. Apply thread sealant, New Holland, part number 82995773, on the retainer bolts of the rear axle bearing and fasten to 6.5 - 8.5 kgf/m. 2. Tighten the sump cover retainer bolts with a torque of 3.7 - 5.0 kgf/m. 3. Tighten the axle retainer bolts with a torque of 19.0 23.0 kgf/m. Installing the P.T.O. one speed shaft: (1) Upper shaft (2) Drive gear (3) Drive gear bearing (4) Bearing cover and retainer (5) Bearing retainer (6) Thin shim (7) Thick shim (8) Sleeve (9) P.T.O. output shaft (10) Output shaft lock ring (11) Bearing (12) Cover (13) 540 RPM driven gear (14) Output shaft front needle bearing

LAIL11TS0003B0A

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Index Power Take-Off (PTO) - 31 Gearbox - 220 Gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Gearbox - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Brakes and controls

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Brakes and controls - 33

[33.120] Mechanical service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1 [33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC TRANSMISSION OIL

Reference Brake drums - Inspect

PAGE 33.1 / 14

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Contents Brakes and controls - 33 Mechanical service brakes - 120

TECHNICAL DATA Mechanical service brakes General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Mechanical service brakes Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brake control pedals and shafts Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Mechanical service brakes Mechanical service brakes - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Adjust freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Brake control pedals and shafts Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Brake drums Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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CONSUMABLES INDEX Consumable NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC TRANSMISSION OIL

Reference Brake drums - Inspect

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PAGE 33.1 / 14

Brakes and controls - Mechanical service brakes

Mechanical service brakes - General specification In oil bath Mechanical + ball in ramp 4 2452.8 cm² (380.2 in²) 38 mm (right and left)

Type of brake Brake operation Brake discs (per side) Total friction brake discs surface Brake pedal clearance

Mechanical service brakes - Torque Component Transmission, brake mechanism attachment bolts Brake pedal bolts Turn buckle counter nut

Specification 66 N·m (49 lb ft) 66 N·m (49 lb ft) 25 N·m (18 lb ft)

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Overview Brakes discs in oil bath are located in each axle housing. There are usually four friction discs per side. Brake actuation is mechanical by means of rod and linkage. The brake is comprised of discs with inner grooves in each axle housing, which have an actuator (1) and an intermediate friction disc (2). The actuator is comprised of two discs with internal cams and steel balls (4). Discs are assembled by means of springs (3) and connected to the actuated lever by two coupling links. The actuated lever is operated by means of the linkage connected to the brake pedals. When depressing the brake pedals, the actuators move in sync with each other, making the balls go up the cam and cause the discs to become separated. When discs are separated , they compress the surfaces against the brake metallic case, stopping the intermediate axle.

Brake lock The brake lock joins both service brake pedals for uniform stopping ability. The brake lock is comprised of a rack on the left brake pedal and a brace located on the right brake pedal. In order to close the latch, both brake pedals must be joined. To release, turn the latch one fourth of a turn and release it to then depress the pedals to release them from the rack.

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RCPH10TTS002AAF

Brakes and controls - Mechanical service brakes

Mechanical service brakes - Exploded view Expanded View - Brake system components (8X2 / 16X4)

LAIL11TS0491F0A

4. A. B.

Brake assembly: Housing inside the brake system Brake disks (sinterized, 3 pieces)

C. D. E.

Actuator disks with internal balls Separator disk (Steel) Housing outside the brake system

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Sectional view Brake Pedal Components

LAIL11TS0015F0A

Brake pedal assemblies

Return spring

Right pedal retention segment

Bush

Left pedal fixing screw

Woodruff key

Washers

Brake pedal transversal shaft

Left lever

10. Bush 11. Arm and parking brake pivot post 12. Parking brake lever guide 13. Parking brake lever

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Inspect Prior operation: Mechanical service brakes - Disassemble (33.120) 1. Clean all components and inspect for damage or wear. Replace as required. 2. Inspect the adjustment of the bolt, the nut and the road threads for damage, rust or wear. Replace as required. Ensure connections are tight. NOTE: Do not attempt to repair and reuse damaged components. Next operation: Mechanical service brakes - Assemble (33.120)

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Test Prior operation: Mechanical service brakes - Adjust freeplay (33.120) 1. Apply the brake lock for uniform braking. 2. Drive the machine a short distance and apply pressure to the brake pedals. The tractor should stop in a straight line. If not, proceed to Mechanical service brakes Adjust (33.120) ; â&#x20AC;&#x153;Freeplay adjustment.â&#x20AC;? Next operation: Mechanical service brakes - Adjust freeplay (33.120)

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Brakes and controls - Mechanical service brakes

Mechanical service brakes - Adjust freeplay WARNING Maintenance hazard! Before performing maintenance on the brake system, chock the traction and steering wheels to prevent machine movement. Failure to comply could result in death or serious injury. W0064A

Prior operation: Mechanical service brakes - Assemble (33.120) Prior operation: Mechanical service brakes - Test (33.120) The brake pedal free play must be 38 mm (1.50 in) with the pedals latched. The tractor must stop in a straight line when both pedals are depressed. If not, adjust as follows: 1. Adjustment is done using the brake rods located under the platform. Chock both rear tires, release the pedals and the parking brake. 2. Release the locking nut from the left side brake (1). Turn the adjusting nut (2) until the freeplay is 38 mm (1.50 in), then tighten the locking nut. 3. Repeat the same operation for the opposite brake.

73118477

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Remove Assembly and installation Assembly and installation of the brake pedals and articulations are done in the reverse order to the removal and disassembly procedure. During assembly and installation, attention must be paid to the following point: Grease the ends of the operating connecting rods and union pins with NLGI 2 grease.

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Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Disassemble Dismounting the brake pedal and brake articulations 1. Block the back wheels and release the parking brake. 2. Disconnect the two return springs (2) of the pedal assemblies (1) situated under the floor. 3. Dismount the cotter pin and the union pin that fix the right brake pedal to the union pin of the brake connecting rod. 4. Dismount the retainer ring and the fixing washer of the right pedal to the brake transversal shaft (3) and remove the pedal on the right side. 5. Remove the left brake pedal lock screw to the transversal shaft. Slide the pedal from the transversal shaft, removing the woodruff key if it is loose in the recess as well as the washer. 6. If necessary, the transversal shaft of the brake can be dismounted according to the following procedure: Remove the retention ring and the union pin that hold the left operating lever to the control fork of the brake connecting rod. Drain the rear axle oil. Pull the differential box shaft using the left brake operating lever.

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LAIL11TS0119A0A

Brakes and controls - Mechanical service brakes

Brake control pedals and shafts - Adjust Service brake â&#x20AC;&#x201C; Adjusting the brake pedals With the brake pedals are locked together, the tractor should stop in a straight line when the brakes are applied. 1. The adjustment is made on the connecting rods situated under the tractor. Block the front and rear wheels, unlock the brake pedals and release the parking brake block. 2. Loosen the jam nut (1) of the left-hand brake yoke, Fig. 1. Turn the adjustment washer (2) until the free play on the left-hand brake pedal is 38 mm. Tighten the jam nut. 3. Repeat on the right-hand brake yoke. LAIL11TS0118A0A

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Brakes and controls - Mechanical service brakes

Brake drums - Inspect Actuator disks and brake disks â&#x20AC;&#x201D; maintenance Check the condition of the brake disks (sintered) in regards to wear and possible distortion. If the lubrication channels in the sintered material of the disks no longer exist, or the existing groove is too small, replace the set of disks. Check the wear of the separator disk (steel), if there are scratches or buckling, replace. NOTE: Before installing new brake disks (sintered material), the disks must be lubricated, kept in a receptacle with the specified oil NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL, so that there is a uniform lubricant film all over the disk when performing the first braking tests of the tractor. Invert the removal and disassembly procedures to assemble the components correctly. Check that lubricating oil does not leak between the transmission and the rear half shaft. Adjust the foot brakes and the parking brake. Test the tractor's brakes, applying equal pressure to the two brake pedals. The tractor should stop in a straight line, without changing direction.

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Index Brakes and controls - 33 Mechanical service brakes - 120 Brake control pedals and shafts - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Brake control pedals and shafts - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Brake control pedals and shafts - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Brake control pedals and shafts - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Brake drums - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Mechanical service brakes - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Mechanical service brakes - Adjust freeplay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Mechanical service brakes - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Mechanical service brakes - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Mechanical service brakes - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Mechanical service brakes - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Mechanical service brakes - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Brakes and controls - 33 Hydraulic service brakes - 202

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

TECHNICAL DATA Hydraulic service brakes Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Brakes Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Torque Tightening torques Components Master cylinder fixing screws Hand brake adjustment lock nut Hand brake fastening bolts Bolts for fastening the hand brake's housing to transmission Bolts on the cover of the hand brake to transmission Cotter nut for hand brake pinion to transmission Brake pedal serration plate bolts

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23 N·m 27 N·m 45 N·m 66 N·m 44 N·m 102 N·m 66 N·m

Brakes and controls - Hydraulic service brakes

Brakes - Assemble Assembly For assembly, invert the disassembly procedure.

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Index Brakes and controls - 33 Hydraulic service brakes - 202 Brakes - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic service brakes - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Brakes and controls - 33 Parking brake or parking lock - 110

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

FUNCTIONAL DATA Hand brake lever Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Parking brake or parking lock Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Brakes and controls - Parking brake or parking lock

Hand brake lever - Static description Parking brake Operation (12 x 12 and 24 x 24 models) There is a hand brake lever on the left side of the driver seat in the models with or without cab that is connected by two cables to the brake control rods (brake pedal adjustment sets) of each rear brake. When pulling the lever, the brake actuators previously described work in the same way as if the foot brakes were pressed.

LAIL11TS0283A0A

LAIL11TS0284A0A

Parking brake tab. The tractor models 8x2 and 16x4 have a tab system on the parking brake. This consists of a serration on the left side brake pedal and a connecting rod situated on the right side of the transmission. To activate the tab, lock the foot brakes together, pull the tab up (1) and run a quarter of a turn. When the foot brakes have been applied, they will lock in the position applied. To disengage roll the tab a quarter of a turn and free them, and apply it at once on the pedals to free them from the serration.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Adjust CAUTION Unexpected machine movement! When the machine is parked and the engine is switched off, the parking brake must be applied. Use wheel chocks if parking on a steep slope. Failure to comply could result in minor or moderate injury. C0014A

Prior operation: Parking brake or parking lock - Assemble (33.110) Adjustment of the parking brake cable control lever travel should be performed each time the parking brake is serviced or repaired, the main brakes are serviced or repaired, or when the idle travel of the lever is excessive. Proceed as follows: 1.

Park the tractor on a flat surface and shut down the engine.

Chock the front wheels using a suitable means.

Raise all four wheels off of the ground and support the tractor with jack stands.

Disconnect the brake pedal connections (1).

Raise the parking brake control lever 3 notches on the quadrant.

Loosen the jam nut (2).

Turn the adjustment nut (1) until wheels lock.

Lower the parking brake control lever and ensure that the wheels can rotate freely.

Apply the parking brake several times to check that the assembly does not get hung up or operate abnormally.

10. Tighten the jam nut and lower the tractor. RCPH09TTS007BAD

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Index Brakes and controls - 33 Parking brake or parking lock - 110 Hand brake lever - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Parking brake or parking lock - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Hydraulic systems

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.106] Variable displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.102] Pump control valves. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.304] Combination pump units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.6 [35.116] Three-point hitch cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.7

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CONSUMABLES INDEX Consumable AMBRA AMBRA AMBRA AMBRA

MULTI MULTI MULTI MULTI

G G G G

Reference Hydraulic systems - General specification Pump control valves - Assemble Pump - Assemble Pump - Install

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Hydraulic systems - 35 Hydraulic systems - 000

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Hydraulic systems - 000

TECHNICAL DATA Hydraulic systems General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Hydraulic systems Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SERVICE Hydraulic systems Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

(*) See content for specific models 73403953 04/04/2014

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CONSUMABLES INDEX Consumable AMBRA MULTI G

Reference Hydraulic systems - General specification

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Hydraulic systems - Hydraulic systems

Hydraulic systems - General specification Hydraulic oil capacities and type Multiple components use the tractor's hydraulic oil. The rear axle, transmission, steering, lubrication system, and the hydraulic system use and disperse oil from the rear axle oil reservoir. NOTE: In areas where prolonged periods of extreme temperatures, local lubricant practices are acceptable. Capacity Maximum capacity (includes filter) Oil type and specifications NEW HOLLAND make NEW HOLLAND specification International specification

66 l/min (17.4 US gpm) 134D AMBRA MULTI G MAT 3525 API GL4, ISO 32/46 (10W30)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Torque Component Hydraulic lift pump drive gear nut Hydraulic lift pump front end–cover mounting bolts Transmission mounted pump retaining bolts Hydraulic lift pump pressure relief valve Engine mounted pump end–cover retaining bolts Engine mounted pump drive gear Engine mounted pump retaining bolts Engine mounted pump inlet tube retaining bolts Control valve front and rear plate retaining bolts Priority valve pack to lift cover retaining bolts Unload valve front plug Flow control valve rear plug Detent shaft pivot coupling Detent housing retaining screws Priority check valve Remote coupler sleeve Remote valve to mounting bracket Remote valve centering spring retaining bolt Remote valve housing to the coupler bolts Outlet piping to the towing brake High pressure outlet piping Low pressure outlet piping Low pressure outlet piping

Torque settings – N m (lb ft or lb in) 50 - 56 N·m (37 - 41 lb ft) 50 - 62 N·m (37 - 46 lb ft) 57 - 76 N·m (42 - 56 lb ft) 60 - 68 N·m (44 - 50 lb ft) 61 - 68 N·m (45 - 50 lb ft) 40 - 45 N·m (30 - 33 lb ft) 57 - 76 N·m (42 - 56 lb ft) 15 - 20 N·m (133 - 177 lb in) 43 N·m (32 lb ft) 57 - 76 N·m (42 - 56 lb ft) 23 - 48 N·m (204 - 425 lb in) 27 N·m (239 lb in) 7 N·m (62 lb in) 7 N·m (62 lb in) 7 N·m (62 lb in) 81 N·m (60 lb ft) 27 - 35 N·m (239 - 310 lb in) 9 N·m (80 lb in) 15 - 20 N·m (133 - 177 lb in) 30 - 32 N·m (22.1 - 23.6 lb ft) 26 - 28 N·m (19.2 - 20.7 lb ft) 43 - 47 N·m (31.7 - 34.7 lb ft) 25 - 30 N·m (18.4 - 22.1 lb ft)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Special tools Tool part number

Tool description 7/16" - 20 M JIC 37Â° x 1/4" - 18 NPT 5000 psi gauge, 2.5 in dial with male disconnect 600 psi gauge Joint sealer

FNH00705 FNH02028 OEM1459 380000583

Hydraulic systems - General specification Flow gear pumps with an integrated steering pump Hydraulic lift main pump Type Gear pump High flow hydraulic Engine 56 l/min to 2374 RPM. pump Low flow hydraulic Engine 35.2 l/min to 2374 RPM. pump Safety valve 176 - 183 bar adjustment pressure Steering pump Type Gear pump Flow 35 l/min Adjustment of the steering motor safety valve located in the orbitrol on the steering column base Tractors without auxiliary front 145 - 183 bar drive Tractors with auxiliary front 166 - 172 bar drive

Hydraulic systems - Torque 7630 8030

LA LA

Special tools Pressure manometer 0 - 30 bar Pressure manometer 0 - 414 bar Pressure test adapter Steering flow rate test adaptor Steering testing pressure adaptor Main pump flow and pressure testing adaptor Main pump flow and pressure testing adaptor Main pump pressure testing adaptor Steering pump flow rate test adaptor Flow meter Tube for Pressure tests Tube for Pressure tests Plug

FT. 8616 FNH 06653 FT. 8503A FNH02028 FT. 8503-8 FNH00705 4FT.852 ( 3/4 in x 18 UNS female by- 3/4 in JIC male) 4FT.853 (JIC of 11/16 in -16 UN by 7/16 in JIC male) 4FT.858 1-14 UNS female for 1/4 in BSP, female 4FT.858/1 JIC of 1/4 in BSP, male for 3/4 in, male 4FT.858/2 JIC of 1/4 in BSP, male for 7/16 in, male 4FT.859 JIC of 13/16 in 16 UN, female, for 3/4 in, male MS.820A or equivalent FNH 02755 Part Nr. 83936707 Part Nr. 83926717 Part Nr. 83900652 73403953 04/04/2014

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Sealant Connections to the remote control valve

Part Nr. 81800812 Obtain through NEW HOLLAND

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview The hydraulic system provides oil flow at regulated pressures for the operation and lubrication of various circuits within the tractor, as well as providing accurate and sensitivity control of implements over a wide range of operating conditions. The standard hydraulic system consists of a top link sensing and three-point linkage system, a fixed displacement tandem (gear type) main pump, an engine mounted auxiliary pump (optional), lift cylinder assembly, and remote control valve(s). The rear axle center casing functions as the hydraulic system reservoir. A lift control valve, and priority valve pack containing several valves, function together to direct the hydraulic oil as needed. A pressure regulator, and various relief and check valves protect the circuits and components from overload conditions, encountered during normal and arduous operation. The configuration and combination of valves prevents oil back flow. The hydraulic system consists of two major circuits: â&#x20AC;˘ High Pressure Circuit (includes optional engine mounted auxiliary pump if equipped) â&#x20AC;˘ Low Pressure, Steering and Lubrication Circuit

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Hydraulic systems - Detailed view High pressure hydraulic pump circuit Operating with a maximum pressure of 182 bar (2639 psi), the high-pressure circuit supplies oil for control of the hydraulic lift assembly, remote control valve(s), and auxiliary equipment (where installed). With more than two remote valves installed on the tractor, it is necessary to supplement the tandem (gear type) transmission mounted pump with an engine mounted auxiliary pump. The front pump within the tandem pump assembly circulates pressurized hydraulic oil to the priority valve group. A relief valve installed in the pump protects the circuit from overload, with an operating pressure of 176 - 182 bar (2552 - 2639 psi). The oil supply from the tandem pump flows to the priority valve group through internal galleries within the hydraulic top cover, while the supply from the optional auxiliary pump flows to the priority valve group through external tubing. – Pump pressurized oil

– Suction oil / return to deposit

RCPH10TTS001FAD

– Trapped oil

High pressure hydraulic circuit component identification and oil flow (1) Position control brace (2) Selector brace (3) Draft control spring (4) Yoke (5) Selector rod and roller assembly (6) Actuator link (7) Safety valve (8) Steering Pump to low pressure circuit

Component identification (9) Hydraulic pump to high pressure circuit (10) Pump intake filter (11) Lifting piston (12) Control valve (13) Exhaust valve (14) Lifting cylinder safety valve (15) Auxiliary pump intake filter (optional) (16) Engine-mounted auxiliary hydraulic pump (optional)

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(17) Check valve (18) Combined valve (sequential) (19) Flow control valve (20) Priority valve group (21) Relief valve (22) Check valve (23) Lifting arms

Hydraulic systems - Hydraulic systems

Low pressure hydraulic pump circuits The low-pressure circuits perform two major functions. They supply pressurized hydraulic oil for the operation of the steering system, Four–Wheel Drive (4WD) clutch, hydraulic Power Take-Off (PTO) clutch, PTO brake, and Dual Command assembly. The low pressure circuits supply lubricating oil to the hydraulic PTO clutch, Dual Command assembly , and the transmission. Before entering the transmission, lubricating oil passes through an oil cooler mounted in front of the radiator. This is an open center system. The low-pressure and lubrication circuits provide a continuous flow of hydraulic oil throughout the system. The rear pump within the tandem gear pump assembly circulates pressurized hydraulic oil through tubing to the steering motor, hydraulic PTO clutch control valve, and to the Dual Command clutch control valve within the transmission housing. A pressure regulating valve in the hydraulic PTO clutch assembly controls oil flow to the lubricating and cooling circuit. In addition, excessive oil in the lubrication circuit discharges to sump through an adjacent relief valve. The relief valve protects the circuit from overloading with a maximum operating pressure of 5.3 bar (76.9 psi). – Pump pressurized oil

– Low pressure oil circuit

RCPH10TTS003GAD

– Lubrication circuit oil

Low pressure hydraulic circuit component identification and oil flow (1) Transmission oil cooler (2) Dual Command valve (3) 4WD solenoid valve (4) Tandem pump (5) PTO supply line

Component identification (6) PTO clutch (7) Low pressure regulating valve (8) Lubrication circuit oil (9) Dual Command assembly (10) Steering motor

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(11) Steering motor safety valve (A) Supply line to steering motor (B) Steering motor return line (C) Supply line to 4WD valve (D) Supply line to Dual Command control valve

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic standard Accurate diagrams of hydraulic circuits are essential to the technician who must repair them. The diagram shows how the components interact. The diagram shows how the system works, what each component should be doing and where the oil should be going so the technician can diagnose and repair the system. There are two types of circuit diagrams: • Cutaway circuit diagrams show the internal construction of the components as well as the flow paths. Using colors, shades or various patterns in the lines and passages, they show many different conditions of flow and pressure. Cutaway diagrams take considerably longer to produce because of their complexity. • Schematic circuit diagrams, the “shorthand” system of the industry, are usually preferred for troubleshooting. A schematic diagram is made up of simple geometric symbols for the components and their controls and connections. There are several systems of symbols used when making schematic diagrams: • ISO – International Standards Organization • ANSI – American National Standards Institute • ASA – American Standards Association • JIC – Joint Industry Conference A combination of symbols from these systems are shown. There are differences between the symbol systems. There is enough similarity, however, so if you understand the symbols shown, you will be able to interpret other symbols as well.

Reservoirs A rectangle with the top removed represents a vented reservoir (A). A rectangle with the top in place represents a pressurized reservoir (B).

RCIL07CCH025AAA

RCIL07CCH027AAA

RCIL07CCH030AAA

RCIL07CCH032AAA

There are other schematic diagrams that show a slightly different version of a pressurized reservoir, but the symbols are similar and easily recognized. An oval with a short line on top or a rectangle with curved sides represents a reservoir that is pressurized.

Lines connected to the reservoir usually are drawn from the top, regardless of where the actual connection is. This symbol shows a line which returns fluid above the level in the reservoir.

If the hydraulic line returns fluid below the level in the reservoir, it is drawn all the way to the bottom of the symbol.

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A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the systems operation.

RCIL07CCH033AAA

RCIL07CCH124AAA

RCIL07CCH034AAA

RCIL07CCH035AAA

RCIL07CCH036AAA

If the pump inlet (B) must be charged or flooded with fluid above the inlet port, the reservoir symbol (A) appears above the pump symbol, and the suction line is drawn out of the bottom of the reservoir symbol. Every system reservoir has at least two hydraulic lines connected to it, and some may have many more. Often the components that are connected to the reservoir are spread all over the schematic. Rather than multiplying lines all over the schematic, individual reservoir symbols are drawn close to the components. The reservoir is usually the only component symbol pictured more than once on a diagram.

Lines, tubes and hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. A working line, such as an inlet pressure or return, is shown as a solid line.

Working lines with arrows show direction of flow. In the first example (A), fluid flows in one direction only; in the second example (B), fluid can flow in both directions.

Pilot or control lines (A) are broken into long dashes. Drain lines (B) for leakage oil are broken into short dashes.

A flexible line is shown as an arc between two dots and is always represented by a solid line.

RCIL07CCH026AAA

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Hydraulic systems - Hydraulic systems

An enclosure outline indicates that there are several symbols that make up a component assembly such as a valve or a valve stack. The enclosure outline is rectangular and is broken with dashes on all sides.

RCIL07CCH028AAA

RCIL07CCH038AAA

RCIL07CCH047AAA

RCIL07CCH048AAA

RCIL07CCH040AAA

RCIL07CCH041AAA

Lines between components are drawn differently when they are crossing or connected. There are lines that cross other lines but are not connected. There are several ways to show crossing lines which are not connected.

Lines that are connected are shown with a dot that represents the connection or shown as a tee connection. The dot connection is the most commonly used when drawing schematic diagrams.

Pumps There are many basic pump designs. A simple fixed displacement pump (A) is shown as a circle with a solid arrow that pointing outward. The arrow points in the direction that the fluid flows. If the pump is reversible (B) or designed to pump in either direction, the symbol has two arrows which point in opposite directions. The pump normally has a pressure port and line (1) from which pressurized fluid is discharged and a suction port and line (2) into which fluid is drawn from the reservoir.

A variable displacement pump (A) is shown by an arrow drawn through the pump symbol at a 45 degree angle. A variable displacement, pressure compensated pump (B) is shown by a small box with an arrow, added to the side of the pump symbol.

If the pump is controlled by a lever (A) or a pedal (B), the appropriate symbol is added to the side of the pump.

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A drive shaft is shown as two short parallel lines extending from the side of the pump. A curved arrow, if present, on the drive shaft indicates the direction of rotation.

RCIL07CCH049AAA

RCIL07CCH051AAA

RCIL07CCH046AAA

RCIL07CCH055AAA

Motors Motor symbols are circles with solid black arrows, which point in the opposite direction of a pumpâ&#x20AC;&#x2122;s arrow, to show the motor as a receiver of fluid. One arrow is used for non-reversible motors (A); and two arrows are used for reversible motors (B).

A simple schematic diagram is shown of a hydraulic motor (A) connected to a hydraulic pump (B).

Cylinders A cylinder is a simple rectangle (A) representing the barrel. The piston and rod are represented by a tee (B), inserted into the rectangle. The symbol can be drawn in any position.

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Hydraulic systems - Hydraulic systems

If the cylinder is single-acting (A), there is only one port shown on the end of the cylinder that receives pressurized fluid. The opposite end of the cylinder is left open. Both ends are closed on a double-acting cylinder (B), and two ports are shown.

RCIL07CCH054AAA

RCIL07CCH057AAA

RCIL07CCH126AAA

RCIL07CCH080AAA

A double rod end cylinder has a rod extending from each end of the rectangle.

Some cylinders have cushions built into them. The cushion slows the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle (A) on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees (B) across the symbol.

Accessories Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the port connections at the corners. A dotted line perpendicular to the flow line represent a filter, strainer or screen.

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A solid line perpendicular to the flow with solid arrows pointing outward represents a cooler.

RCIL07CCH081AAA

RCIL07CCH118AAA

RCIL07CCH119AAA

RCIL07CCH130AAA

The symbol for a heater is like the symbol for a cooler, except the solid arrows point inward.

Two sets of arrows pointing inward and outward represents a temperature control unit The solid arrows point in the direction that heat is dissipated. Or in the case of the control unit, they show that heat can be regulated.

An oval with details inside represents an accumulator. The details explain what type of accumulator it is: spring loaded (A), gas charged (B), or other features. The divider line indicates there is a separator between the charge and the fluid. A hollow arrow indicates gas. A spring indicates that the accumulator is spring-loaded.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol Line and line functions Solid line - main line

Dotted line - exhaust or drain line

Dashed line - pilot line

Enclosure outline

Lines crossing

Lines joining

Lines crossing

Liquid direction of flow

Gaseous direction of flow

Flexible line

Mechanical devices Connections (two parallel lines) for shafts, levers, etc.

Variable component (arrow intersects symbol at 45 Â°)

Spring

Pumps and motors Pump, fixed displacement

Pump, variable displacement

Pressure compensated, variable displacement pump

Fixed displacement pump (bidirectional flow)

Motor, fixed displacement

Motor, variable displacement

Oscillator

Reservoirs

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Hydraulic systems - Hydraulic systems

Reservoir, open to atmosphere

Pressurized reservoir

Return line to reservoir below fluid level

Return line to reservoir above fluid level

Cylinders Single acting

Double acting, single rod end

Double acting. double rod end

Single rod end, fixed cushion both ends

Single rod end, adjustable cushion, rod end only

Differential cylinder

Valves Check valve

Pilot-operated check valve

On/Off manual shut off valve

Regulating or selector valves

2 position, 2 way valve

2 position, 3 way valve

2 position, 4 way valve

3 position, 4 way valve

2 position, 4 way open center, crossover valve

Valve capable of infinite positioning (indicated by horizontal lines parallel to the envelope)

Pressure relief valve

Pressure reducing valve

Non-adjustable restrictor valve

Adjustable restrictor valve

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Hydraulic systems - Hydraulic systems

Adjustable restrictor, pressure compensated

Adjustable restrictor, temperature and pressure compensated

Valve actuators Solenoid

Detent

Spring

Manual

Push button

Lever

Pedal

Mechanical

Pressure compensated

Pilot pressure, remote supply

Liquid supply

Accessories Filter

Cooler

Heater

Temperature controller

Accumulator (hydropneumatic

Reversing motor

Station or test point

Pressure indicator

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Hydraulic systems - Hydraulic systems

Temperature indicator

Pressure switch

Quick disconnect (disconnected)

Quick disconnect (connected)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema Hydraulic system schematic – Maximum 49 l/min (13 US gpm) pump supply

– Return to tank/sump

RCIL10TTS002GAD

– Maximum 26 l/min (7 US gpm) pump supply

Hydraulic tandem pump, steering motor valve, and Dual Command valve (optional) assemblies Component reference (A) (A1) (A2) (B) (B1) (C) (C1) (C2) (C3) (D) (E) (F)

Component Dual Command valve assembly Under drive (tortoise gear) Direct drive (rabbit gear) Tandem pump (fixed displacement) – 49 l/min (13 US gpm) and 26 l/min (7 US gpm). Pressure relief valve – 176 - 182 bar (2552 - 2639 psi) Steering motor valve assembly Two-Wheel Drive (2WD) steering cylinder Four-Wheel Drive (4WD) steering cylinder (optional) Regulator differential pressures Tandem gear filter with bypass valve – 0.48 bar (7 psi) Flow to priority valve and three point hitch lifting valve assemblies Flow to Power Take–Off (PTO) clutch valve and Four-Wheel Drive (4WD) valve assemblies

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Hydraulic systems - Hydraulic systems

– * Maximum 49 l/min (13 US – Return to tank/sump – Maximum 35 l/min (9.2 US gpm) pump supply gpm) pump supply * tractors equipped with an auxiliary pump have a maximum flow of 83 l/min (22 US gpm) between the priority valve assembly and the remote valves.

RCIL10TTS001GAD

Hydraulic priority valve, three point hitch lifting valve, and remote valve assemblies Component reference A(A) (A1) (A2) (A3) (B) (B1) (B2) (C) (C1) (C2) (D) (E) (F) (G)

Component Three point hitch lifting valve assembly Lifting cylinder Three point hitch lifting valve Pressure relief valve – 176 - 182 bar (2552 - 2639 psi) Priority valve assembly Priority valve Combined valve Remote valve assembly Remote valve – maximum flow capacity 49 l/min (13 US gpm) ** Remote valve – maximum flow capacity 49 l/min (13 US gpm) ** Flow from tandem pump Ram cylinders Auxiliary pump (optional) Hydraulic flow test port

** Maximum flow capacity 57 l/min (15 US gpm) with auxiliary pump.

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Hydraulic systems - Hydraulic systems

– Maximum 26 l/min (7 US gpm) pump supply

– Return to tank/sump

RCIL10TTS003GAD

– Lubrication oil supply

Hydraulic PTO clutch valve and Four-Wheel Drive (4WD) valve assemblies Component reference (A) (A1) (A2) (A3) (A4) (A5) (B) (C) (D) (E) (F)

Component Power Take-Off (PTO) clutch valve assembly Power Take-Off (PTO) control valve Pressure regulator valve – 12 - 15 bar (174 - 218 psi) Safety valve – 5.3 - 8.5 bar (77 - 123 psi) Power Take-Off (PTO) clutch Power Take-Off (PTO) brake Four-Wheel Drive (4WD) valve assembly (optional) Oil cooler Transmission Flow from tandem pump – 26 l/min (7 US gpm) pump supply Power Take-Off (PTO) lubrication

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview Description/Location Safety Valve Control valve spool and liner

Identification Hydraulic pump Hydraulic lift cylinder assembly

Exhaust valve Safety Valve

Auxiliary services control valve (VSA)

Outflow valve

Priority valve assembly

Flow control valve

Sequence valve

Check valve

Auxiliary pump check valve

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Function Limits the maximum pressure in the high pressure circuit. Pressure of 190 bar. Provides four control positions: neutral, lower, slow raise and fast raise. Maintains a constant controlled supply. Protects the lifter circuit against overload when the system is in neutral. Opening pressure: 210 bar. The valve has two positions: when it is pulled out, it stops oil entering and exiting the lift cylinder and when it is pushed in (internal), it releases the flow of oil. Used as a safety device when transporting equipment on the hydraulic lift. Controlled by the pressure of the oil that passes through the control valve. Pressure of 4.2 - 21 bar. 48 mm spring. Controls the oil flow to the hydraulic lift by restricting the oil flow to the sequence valve. 73 mm spring. Regulates the oil flow to the remote control valves and diverts the excess pressure to the tank. Controls the maximum hydraulic pressure to the control. Controls the oil flow into the lift cylinder; functions with the hydraulic lift control valve ( 5 - 6 bar). Allows the oil pressure from the auxiliary pump to pass through the high pressure circuit (remote control) and prevents the hydraulic pump pressure from returning to the auxiliary pump (when installed).

Hydraulic systems - Hydraulic systems

Hydraulic systems - Overview The hydraulic system provides oil flow at regulated pressures for the operation and lubrication of various circuits within the tractor, as well as providing accurate and sensitivity control of implements over a wide range of operating conditions. The standard hydraulic system consists of a top link sensing and three-point linkage system, a fixed displacement tandem (gear type) main pump, an engine mounted auxiliary pump (optional), lift cylinder assembly, and remote control valve(s). The rear axle centre casing functions as the hydraulic system reservoir. A lift control valve, and priority valve pack containing several valves, function together to direct the hydraulic oil as needed. A pressure regulator, and various relief and check valves protect the circuits and components from overload conditions, encountered during normal and arduous operation. The configuration and combination of valves prevents oil back flow. The hydraulic system consists of two major circuits: • High Pressure Circuit (includes optional engine mounted auxiliary pump if equipped) • Low Pressure, Steering and Lubrication Circuit

Hydraulic circuits This line of tractors features four main hydraulic circuits: • High Pressure or Hydraulic Lift Hydraulic Circuit; • Hydrostatic Steering Circuit; • Low Pressure Circuit; • Lubrication Circuit The High Pressure Hydraulic Circuit serves the three point hydraulic lift, the remote hydraulic valves and trailer brakes (when available). Its characteristic is to operate under high pressure during long periods. The steering circuit can only drive the direction front shaft (hydrostatic steering) or supply the hydrostatic steering and the low pressure circuit. It normally operates under low pressure with high pressure peaks. The low-pressure circuit turns off the auxiliary front-wheel drive, and activates the power take-off, differential lock, and transmission hydraulic clutches (when fitted). On some models, an independent circuit formed by a hydraulic gear pump mounted on the rear shaft, on others it is hydraulically supplied by the return from the steering circuit. The latter is standard and the former is available only as an optional item for some markets. It usually operates under low pressure, that is, around 1 tenth of the High Pressure Hydraulic Circuit pressure. The lubrication circuit is supplied by the excess flow rate from the low pressure circuit and is considered to be one of its sub-circuits.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Bleed Purging remote cylinders When a new cylinder is installed, to replace a trapped cylinder that has remained out of service for a long time or with the hoses disconnected, it will be necessary to bleed the system to remove the air from it. With the hoses connected to the remote control valve couplings, put the cylinder with the hose side turned up and extend or retract the cylinder seven or eight times, using the remote control valve lever. Check the rear axle oil level before and after putting a remote cylinder to work.

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Pressure test Pressure tests The hydraulic pressure of the automatic disarm activator must be regulated when the valve set is serviced or when the control levers and rod prematurely return to neutral. Perform the test according to the following procedure, Refer to Fig. 1. 1. Install the inlet tube of a flowmeter (4) in the top coupler of the set to be tested. Set the flow control lever (5) to maximum flow. 2. Install the flowmeter return tube (2) on the top coupler of the other group of remote control valves. 3. Completely open the flow meter load valve (3). 4. Run the engine at 1700 RPM. Put the lever of the valve assembly to which the flowmeter RETURN is coupled, in the FLOTATION position. Put the lever of the valve assembly to which the flowmeter INLET is coupled, in the LIFTING position. 5. Adjust the flowmeter load valve to a pressure of 140 bar and keep the engine running until a temperature of 75 °C is attained. 6. Gradually close the load valve and record the disarm pressure of the remote control lever. The disarm pressure should be between 148 - 162 bar. 7. To adjust the pressure: 8. Turn off the engine of the machine. • To INCREASE the pressure FASTEN the retainer screw (1). • To REDUCE the disarm pressure, LOOSEN the screw (1) by turning it in the anti-clockwise direction Each half a turn of the screw is equivalent to approximately 32 bar. NOTICE: Never adjust the retainer screw with the machine running.

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Hydraulic systems - Hydraulic systems

LAIL11TS0007F0A

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Pressure test Pressure testing In the following tests, ensure the tractor's hydraulic oil is at operating temperature, the transmission and hydraulic system are in neutral, and the power take-off is switched off.

Dual Power system pressure test (testing the low pressure hydraulic circuit) 1. Remove the pressure switch (1) from the low pressure hydraulic circuit, Fig. 1.

LAIL11TS0014A0A

LAIL11TS0015A0A

LAIL11TS0016A0A

2. Install a 30 bar pressure gauge in place of the low pressure circuit pressure switch (steering return). 3. Set the engine speed to 2100 RPM and take a pressure reading. A reading of 18 - 25 bar should be registered. (1) Gauge, FT.8616 (2) Adapter FT8503 or FNH 00705 (2) (3) Test tubes, part nos. 83936707 and 83966717.

Transmission lubrication pressure test 1. Start the tractor and set the engine speed to 1000 RPM. Stop the engine, but do not readjust the accelerator. 2. Connect a 30 bar pressure gauge FT.8616 (5) on the oil radiator inlet pipe, Fig. 3. 3. With the aid of an assistant, start the engine and take a reading from the pressure gauge. Take the pressure reading quickly then switch off the tractor. The pressure recorded should be 5.0 - 8.0 bar, depending on the engine speed. The minimum operating pressure of the lubrication circuit safety valve, located in the PTO valve and clutch assembly, is 5.0 - 8.0 bar.

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic systems - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Hydraulic systems - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic systems - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Hydraulic systems - Hydraulic standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic systems - Hydraulic symbol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Hydraulic systems - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Hydraulic systems - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Hydraulic systems - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Hydraulic systems - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Hydraulic systems - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Hydraulic systems - 35 Variable displacement pump - 106

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Variable displacement pump - 106

SERVICE Variable displacement pump Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - Variable displacement pump

Variable displacement pump - Flow test Prior operation: Variable displacement pump - Install (35.106) 1. Install a test hose to the flow meter inlet port and to one of the upper ports of the remote valve. Install another test hose to the flow meter's outlet port and to the lower port on the same remote valve. 2. Adjust the flow control on the corresponding remote valve to maximum flow. 3. Fully open the flow meter's load valve. 4. Start the engine and adjust engine speed to 2100 RPM. 5. Place the corresponding remote valve control lever in a float position (fully forward). Confirm the flow meter reading is indicating 57 l/min (15 US gpm) which is the maximum flow rate for a remote valve. NOTE: If not within specifications remove the auxiliary pump [refer to Variable displacement pump - Prepare (35.106) for removal procedure] and test the tandem pump alone to determine which pump is not working properly and overhaul it. See Pump - Pressure test (35.304) to find out the procedure. Repeat the test procedure. 6. Turn engine off, release pressure in the hydraulic lines and disconnect the flow meter.

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Index Hydraulic systems - 35 Variable displacement pump - 106 Variable displacement pump - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Pump control valves - 102

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Contents Hydraulic systems - 35 Pump control valves - 102

FUNCTIONAL DATA Pump control valves Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Pump control valve Priority/Regulator valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE Pump control valves Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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CONSUMABLES INDEX Consumable AMBRA MULTI G

Reference Pump control valves - Assemble

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PAGE 35.3 / 25

Hydraulic systems - Pump control valves

Pump control valves - Dynamic description Control valve oil flow – Neutral With the control valve in the neutral position, the following functions occurs: • The trapped hydraulic oil within the lift cylinder holds the cylinder in the desired position. • Pressurized oil enters the combining valve, located in the priority valve pack on top of the hydraulic lift cover. The combining valve either returns the oil to the reservoir, or directs it to the remote valve(s), depending on demand. • Hydraulic circuits without remote valves installed, do not require a combining valve. With the control valve in the neutral position, the following oil flow occurs: • Pump pressure enters the lift cover at Gallery E, where the control valve prevents the oil from entering Galleries C and D. • Pressurized oil flows up Gallery E to the flow control valve and unload valve. • The unload valve opens to return at the left side via Gallery C, and the control valve center. • Oil pressure applied to the center face of the spool in the unload valve holds the spool to the left. • With the unload valve held to the left, oil in Gallery D, and in the spring-loaded end of the flow control valve, returns to sump through Gallery G, by way of a small internal drilling in the unload valve. • Oil pressure in Gallery E now acts on the right-hand face of the flow control valve via an internal drilling, and moves the valve full left, which allows the oil to flow from Gallery E to Gallery F. • With the remote valve(s) in neutral, the load sensing, line pressure vents to sump through the remote valve(s). Pressurized oil in Gallery F acts on the right-hand side of the combining valve, and moves the valve to the left, which ports oil from Gallery F to return through Gallery G. • The oil in the lift cylinder remains trapped in Galleries A and B by the control valve land, and the check valve. – Pump pressurized oil – Trapped oil – Suction oil / return to deposit – Auxiliary pump oil (if equipped) 1. 2. 3. 4. 5. 6.

To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

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

Exhaust valve To lift cylinder Non return valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

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Hydraulic systems - Pump control valves

RCPH10TTS005HAD

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Hydraulic systems - Pump control valves

Control valve oil flow – Lowering position With the control valve in the lowering position, the following functions occurs: • Pressurized oil enters the combining valve, located in the priority valve pack on top of the hydraulic lift cover. The combining valve either returns the oil to the reservoir, or directs it to the remote valve(s), depending on demand. • Hydraulic oil within the lift cylinder returns to sump through the control valve and exhaust valve. With the control valve in the lowering position, the following oil flow occurs: • Pump pressure enters the lift cover at Gallery E, where the control valve prevents the oil from entering Galleries C and D. • Pressurized oil flows up Gallery E to the flow control valve and unload valve. • The unload valve opens to sump on the left side via Gallery C, and the control valve center. • Oil pressure applied to the center face of the spool forces the spool to the left. • With the unload valve held to the left, oil in Gallery D, and in the spring-loaded end of the flow control valve, returns to sump through Gallery G, by way of a small internal drilling. • Oil pressure in Gallery E acts on the right-hand face of the flow control valve via an internal drilling, which moves the valve full left, allowing the oil to flow from Gallery E to Gallery F. • In both the neutral and lowering positions, a lack of demand from the remote valve(s) will cause the combining valve to discharge hydraulic oil back to sump. • As the control valve moves to the right from neutral to the lowering position, lift cylinder oil flows out of Galleries A and B, through the control valve, and on to sump through the exhaust valve. • Excess oil flow from the lift cylinder through the exhaust valve forces the valve down against the spring, which reduces the exhaust port aperture.The reduced exhaust port aperture consequently controls the lowering of the lift arms irrespective of the loading on the lift linkage. – Pump pressurized oil – Trapped oil – Suction oil / return to deposit – Auxiliary pump oil (if equipped) 1. 2. 3. 4. 5. 6.

To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

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

Exhaust valve To lift cylinder Non return valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

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Hydraulic systems - Pump control valves

RCPH10TTS006HAD

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Hydraulic systems - Pump control valves

Control valve oil flow – Raise position (slow) When raising the hydraulic lift, two conditions occur, referenced as slow and fast raises. The number of open ports in the control valve that direct pressurized oil to the lift cylinder determines the speed of the lift. Moving the lift control lever to the point where the hydraulic lift begins to raise, engages the slow lift and the following functions occur: • Pressurized oil flows to the lift cylinder or combining valve. • The position of the control valve determines the position of the flow control valve, giving priority to lift cylinder demand, and diverting the surplus oil to the combining valve. • The combining valve either returns the surplus oil to the reservoir, or directs it to the remote valve(s), depending on demand. With the control valve in the slow raise position, the following oil flow occurs: • The initial movement of the lift control lever shifts the control valve from the neutral to the slow raise position. This allows pressurized oil from Gallery E to flow to Gallery C through a drilled passage in the control valve, and the left-hand end of the unload valve. • The combination of spring pressure in the unload valve, and oil pressure in Gallery C, shifts the unload valve spool full right, connecting Galleries E and D through a large cross drilling. • The channel drilled in the unload valve restricts the hydraulic oil flow to 7.6 l/min (2.0 US gpm), which induces a smooth initial lift. The reduced pressure acts on the left-hand face of the flow control valve spool, and moves it to the right. The initial oil flow from the flow control valve enters Galleries A and B through a check valve. • Further movement of the control valve to the left, uncovers a series of ports connecting Gallery E with Gallery D. Oil flow increases into Gallery D, which speeds up the lift cylinder movement. The flow control valve moves further to the right, reducing oil flow from Gallery E to Gallery F. – Pump pressurized oil – Trapped oil – Suction oil / return to deposit – Auxiliary pump oil (if equipped) 1. 2. 3. 4. 5. 6.

To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

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

Exhaust valve To lift cylinder Non return valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

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Hydraulic systems - Pump control valves

RCPH10TTS007HAD

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Hydraulic systems - Pump control valves

Control valve oil flow – Raise position (fast) When raising the hydraulic lift, two conditions occur, referenced as slow and fast raises. The number of open ports in the control valve that direct pressurized oil to the lift cylinder determines the speed of the lift. Moving the lift control lever fully backward engages the fast lift position bypassing the slow lift, and the following functions occur: • The flow control valve gives full priority to the lift cylinder. • At this point, operation of the remote valve(s) would only be possible with an additional auxiliary engine mounted pump installed. With the control valve in the fast raise position, the following oil flow occurs: • The full rear movement of the lift control lever shifts the control valve pass the slow raise position to the fast raise position. All the ports in the control valve bushing uncover, allowing increased pump oil flow from Gallery E to Gallery D. • The combination of spring pressure in the unload valve, and oil pressure in Gallery C, shifts the unload valve spool full right, connecting Galleries E and D through a large cross drilling. • Oil flows from Gallery E to Gallery D with less restriction and the pressure on both sides of the flow control valve equalizes. The flow control vale spring moves the spool to the full right position, closing off Gallery E from Gallery F. • All pressurized oil from the pump diverts to the lift cylinder through Gallery A, giving the lift cylinder priority over the remote valve(s). • The size of the ports in the flow control valve bushing limit the oil flow to the lift cylinder to a maximum of 31.0 l/min (8.2 US gpm). • The completely closed off Gallery F allows the combining valve to move to the right, preventing oil flow to sump through Gallery G, unless there is an auxiliary engine mounted pump installed. – Pump pressurized oil – Auxiliary pump oil (if equipped) – Suction oil / return to deposit 1. 2. 3. 4. 5. 6.

To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

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

Exhaust valve To lift cylinder Non return valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

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Hydraulic systems - Pump control valves

RCPH10TTS008HAD

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Hydraulic systems - Pump control valves

Control valve oil flow with auxiliary engine mounted pump (if equipped) The optional auxiliary engine mounted pump supplements pressurized oil to the remote valve(s) circuit. • A pilot (load sensing) signal applied to the left end of the combining valve moves the valve to the right. This blocks the connections of Gallery F to G and Gallery H to G progressively, depending on the hydraulic requirements of the remote valve(s). • Pressurized oil from the auxiliary pump enters the priority valve pack and forces open the remote valve feed checkvalve open to combine with oil flow from the main pump in Gallery F. • With the remote valve(s) circuit in neutral, the load sensing line vents, and pump oil pressure in Gallery F moves the combining valve to the left, opening pump oil flow to return through Gallery G. • The relief valve within the combining valve vents oil to return through Gallery G, if pressure exceeds 182 bar (2639 psi) in the load sensing line, or if there is an overload in the remote circuit. The change in pressure across the combining valve moves the spool to the left, allowing excess oil flow from both pumps in Galleries F and H to be exhausted to return through Gallery G. – Pump pressurized oil – Auxiliary pump oil (if equipped) – Suction oil / return to deposit 1. 2. 3. 4. 5. 6.

To remote valves Combining valve Flush valve Flow control valve From main pump Control valve

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

Exhaust valve To lift cylinder Non return valve To rear axle reservoir Remote valve pilot (load sense) line From auxiliary pump (if equipped)

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Hydraulic systems - Pump control valves

RCPH10TTS008HAD

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Hydraulic systems - Pump control valves

Pump control valves - Overview 7630 8030

LA LA

Priority valve assembly When the tractor is equipped with a gear hydraulic pump, it needs a set of priority valves, Fig. 1. This set, which is found under the hydraulic lift cover, has a set of valves that establishes the priorities of the pump and controls the flow of oil to the lift cylinder and remote control valves. The function of each of these valves is indicated below:

Flow control valve (4) This valve, which is in the priority valve set, controls the oil flow to the hydraulic lift cylinder, closing the passage of oil to the remote control. The flow control valve, assures that priority is given to feeding the hydraulic lift and sends the excess oil to the sequence valve.

Outflow valve (3) The outflow valve is controlled by the pressure of the oil sent by the control valve and has two positions. In the raise position the valve allows the pumped oil to pass to the lift cylinder, while in the neutral position or lowering position, the oil goes to the deposit.

LAIL11TS0408A0A

1. 2. 3. 4.

Non return valve Sequence valve Outflow valve Flow control valve

Sequence valve (2) This valve, which is only installed if the tractor is equipped with remote control valves, regulates the oil flow in the remote control circuit, and combines the oil flow coming from the main pump with that from the auxiliary pump (optional). The functions of the sequence valve are: • Return the oil flows from the main pump and the auxiliary pump to the sump when there is no request from the remote valve. • To direct the oil to the remote control valves when there is a request. • Direct part of the flow from the pump to the remote control valves and return the excess oil to the rear axle if the pump output exceeds the flow required. • Protect the Control circuit of the auxiliary pump from excess pressure.

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Hydraulic systems - Pump control valves

Check valve (1) There are two retention valves incorporated into the priority valve set as follows:The first retention valve that is situated in the auxiliary pump feed orifice in the priority valve set, prevents the flow from the main pump from meeting that of the auxiliary pump. The second retention valve that is situated at the base of the priority valve set, avoids the flow of oil from the Lift cylinder to the flow control valve during Lift cylinder lowering, neutral in case of shock, due to the load conditions. Description/location Safety Valve

Identification Hydraulic pump.

Control Valve Spindle and sleeve Exhaust valve Safety Valve Hydraulic lift cylinder set

Auxiliary services control valve (ASV)

Outflow valve

Flow control valve

Sequence valve Priority valve assembly Non return valve

Auxiliary pump retention valve

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Function Limits the maximum pressure in the high pressure circuit 190 bar pressure. Provides four control positions: neutral, lowering, slow rise and fast rise. Maintains constant controlled lowering Protects the lift circuit against overload when the system is in neutral. Opening Pressure: 210 bar The valve has two positions: when pulled it locks, impedes the entry and exit of oil from the lift cylinder and when pushed (internal) releases the passage of oil. Used as a safety device during transport of equipment in the hydraulic lift. Controlled by the pressure of the oil that passes through the control valve. 4.2 - 21 bar pressure. 48 mm spring. Controls the oil flow to the hydraulic lift by restricting the oil flow to the sequence valve. 73 mm spring. Regulates the oil flow to the remote control valves, diverts the excess pressure to the tank. Controls the maximum hydraulic pressure to the control. Controls the oil flow into the lift cylinder; functions as a hydraulic lift control valve ( 5 - 6 bar). Allows the oil pressure from the auxiliary pump to pass through the high pressure hydraulic circuit (remote control) and prevents the hydraulic pump pressure from returning to the auxiliary pump (when installed).

Hydraulic systems - Pump control valves

Pump control valve Priority/Regulator valve - Exploded view The priority valve group (PVG), located on top of the hydraulic lift cover contains a set of valves, that establishes pump oil priority, and controls the flow of oil to the lift cylinder, remote valves, and auxiliary equipment.

Flow control valve (FCV) The flow control valve, located in the priority valve group, controls oil flow to the lift control valve, by sensing pressure variations. The flow control valve also diverts surplus oil to the combining valve.

Unload valve (UV) The unload valve, located in the priority valve group, responds to flow control valve movement, and operates in two positions. In the raised position, the valve allows oil to flow to the lift cylinder. In the neutral or lowering position, the valve directs oil to the reservoir (rear axle center casing).

Combining valve (CV) The combining valve regulates the flow of oil to the remote valve circuit, and combines the flow of oil from the main and auxiliary pumps as required. The combining valve performs the following functions: • Directs main hydraulic and optional auxiliary pump oil flow to remote circuits on demand, and returns oil flow to sump when no demand exists. • Directs oil flow to sump if pump output exceeds remote circuit demand. • Protects the remote circuits and auxiliary pump circuit from excessive pressure.

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Hydraulic systems - Pump control valves

RCPH10TTS013FAD

(1) Priority valve group (PVG) (2) Flow control valve (FCV) spool (3) FCV hex socket plug (4) Auxiliary pump circuit (APC) check valve plug with O-ring (5) APC check valve spring stop (6) APC check valve spring (7) APC check valve ball (8) PVG restrictor

(9) PVG restrictor O-ring and plug (10) Lift circuit (LC) check valve seat/slot and O-ring (11) LC check valve spring (12) LC check valve spacer with plug (13) LC check valve cage (14) LC check valve ball (15) Combined valve (CV) spool with internal relief valve (16) CV spring

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(17) CV plug and O-ring (18) APC check valve plug with O-ring (19) Unload valve (UV) plug with O-ring (20) UV spring LC check valve spring (21) UV spool with O-ring (22) FCV plug with O-ring (23) FCV spring

Hydraulic systems - Pump control valves

Pump control valves - Prepare DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

WARNING Uncontrolled equipment movement! Before disconnecting the hydraulic hoses from the tractor: -Lower the implement to the ground; OR, -Install the transport stops and place the hydraulic remote lever in the float position. Failure to comply could result in death or serious injury. W0907A

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

NOTICE: Contamination in the hydraulic system is a major cause of hydraulic component malfunction. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: (A) Draining or filling the hydraulic reservoir. (B) Disconnecting hydraulic hoses or connectors. (C) Disassembling hydraulic components. (D) Damaged or worn seals. It is critical to work in a clean environment and thoroughly clean the area around any component that will be serviced. 1. Park the tractor on level ground. Turn the engine off. Chock the front and rear wheels. 2. Move the hydraulic controls back and forth a few times to release the pressure in the hydraulic lines. 3. Remove the four sets of bolt hardware that secures the operator seat and base plate to the platform. 4. Disconnect the operator's seat electrical harness connection below the platform. Remove the seat assembly from the tractor.

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Hydraulic systems - Pump control valves

5. Thoroughly clean the area around the control valve's mounting location and hose connections. 6. Be prepared to cap or plug the control valve hoses and connectors that will be disconnected.

RCPH09TTS247AAD

Next operation: Pump control valves - Remove (35.102)

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Hydraulic systems - Pump control valves

Pump control valves - Remove Prior operation: Pump control valves - Prepare (35.102) 1. Disconnect and plug the remote valve feed hose (1), load sensor tube (pilot line) (2), and the auxiliary supply hose (if equipped) (3).

RCPH09TTS247AAD

2. Remove the control valves mounting hardware. Lift the control valve off the hydraulic lift cover. Next operation: Pump control valves - Disassemble (35.102)

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Hydraulic systems - Pump control valves

Pump control valves - Disassemble Prior operation: Pump control valves - Remove (35.102)

RCPH10TTS013FAD

NOTE: When disassembling the control valve, lay components out in the order of removal to facilitate a quick and easy reassembly. Perform the following procedure on a clean smooth surface. 1. Remove the lift circuit check valve. A. Remove plug and spacer (12). B. Remove the valve cage (13), spring (11), ball (14), and seat/slot with O-ring (10). 2. Remove the flow control valve. A. Remove the plug and O-ring (22). B. Remove the spring (23). C. Remove the spool (2) and hex socket plug (3). 3. Remove the unload valve. A. Remove the plug and O-ring (19). B. Remove the spring (20). C. Remove the spool and O-ring (21). 73403953 04/04/2014

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Hydraulic systems - Pump control valves

4. Remove the combining valve. A. Remove the plug and O-ring (17). B. Remove the spring (16). C. Remove the spool and O-ring (15). 5. Remove the auxiliary pump circuit check valve. A. Remove the plug and O-ring (18). B. Remove the auxiliary pump check valve plug with O-ring (4)or if equipped hose fitting. C. Remove spring stop (5), spring (7), and ball (6). 6. Remove the priority valve restrictor. A. Remove the plug and O-ring (9). B. Unscrew and remove the restrictor (8). Next operation: Pump control valves - Overhaul (35.102)

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Hydraulic systems - Pump control valves

Pump control valves - Overhaul DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump control valves - Disassemble (35.102) 1. Clean all components in a suitable solvent. Allow parts to dry. 2. Inspect the valve bores, plugs and caps for damage or burrs. Remove minor burrs or scratches with a fine abrasive. Any heavy scoring of the bores necessitates replacement of the priority valve pack. 3. Inspect the valve springs for wear, damage or deformity. 4. Inspect oil passages and ports for obstructions. Next operation: Pump control valves - Assemble (35.102)

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Hydraulic systems - Pump control valves

Pump control valves - Assemble DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump control valves - Overhaul (35.102)

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Hydraulic systems - Pump control valves

RCPH10TTS013FAD

NOTICE: Install spools into valves using gentle pressure and rotation. Excessive force will damage the valves. 1. Replace all O-rings and seals. Coat O-rings with petroleum jelly. Confirm O-rings are seated properly (where installed). 2. Lubricate all parts with clean 134D AMBRA MULTI G hydraulic oil. 3. Install the lift circuit check valve. A. Install the O-ring and seat (10), ball (14), spring (11), and cage (13). B. Install spacer with plug (12). 4. Install flow control valve. A. Slide the spool (15) into the flow control valve. B. Insert the spring (16) in the valve front. C. Screw in the rear plug (3) by one thread. D. Install the front plug with O-ring (22) completely and tighten. E. Tighten the rear plug (3) to a torque of 27 NÂˇm (239 lb in).

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Hydraulic systems - Pump control valves

5. Install the unload valve. A. Insert the unload valve spool with O-ring (21) small end first. B. Insert the spring (20) into the valve front. C. Install the front plug with O-ring (19) and tighten to a torque of 23 - 48 NÂˇm (204 - 425 lb in). 6. Install the combining valve. A. Insert the combining valve spool (15) with the relief valve assembly headfirst. B. Insert the spring (16) into the valve front. C. Install the end cap with O-ring (17) and tighten to a torque of 27 NÂˇm (239 lb in). 7. Install the check valve (auxiliary pump circuit if equipped). A. Insert the ball (7), spring (6), and spring stop (5) into the rear of the check valve. B. Install the plug with O-ring (4) and tighten. Next operation: Pump control valves - Install (35.102)

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Hydraulic systems - Pump control valves

Pump control valves - Install DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump control valves - Remove (35.102) 1. Install new O-rings on top of the hydraulic lift cover. Position the control valve on top of the hydraulic lift cover. 2. Install the control valve mounting bolt hardware and tighten to a torque of 57 - 76 NÂˇm (42 - 56 lb ft). 3. Attach the previously removed hoses. Remote feed line (1), load sensor tube (pilot line) (2), and auxiliary feed (3) (if equipped).

RCPH09TTS247AAD

4. Connect the operator seat to the electrical harness previously disconnected. 5. Install the operator seat and base plate and secure the seat assembly to the platform.

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Hydraulic systems - Pump control valves

6. Check hydraulic oil fluid level and fill if needed. A. Remove the filler plug (1). B. Fill with oil, checking the level with the dipstick (2). The oil level should be between the marks (3) on the dipstick. Maximum oil capacity: 66 l (17.4 US gal) NOTE: When operating remote cylinders, the rear axle oil level will be affected. When adding oil to the rear axle to accommodate the oil requirement of remote cylinders, no more than 45 l (11.9 US gal) should be added to bring the oil level up to within the marked area on the dipstick when all cylinders are fully extended. Alternatively, remote cylinders with the total oil capacity of up to 18 l (4.8 US gal) may be connected to the hydraulic system without adding oil, provided that the tractor is being operated on level ground.

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SMG114

Hydraulic systems - Pump control valves

Pump control valves - Pressure test Testing the steering safety valve pressure ATTENTION: There is no safety valve in the steering pump and the following pressure test can only be performed as set out below. Failure to comply with these precautions could result in serious damage to the hydraulic pump. 1. Turn steering completely to the left. 2. Install a suitable pressure gauge on the flexible feed hose from the steering piston (left-hand side) using the connections. 1.

Pressure gauge of 413.8 bar (6000 psi)

Adapter FT8503-8

Male 7/16 JIC x Male 9/16 JIC

LAIL11TS0409A0A

3. Start the tractor and run the engine at 1500 RPM. Turn the steering wheel to the left and hold it with a force of 2.25 kgf. Take the manometer pressure readout. NOTE: Using a force of more than 2.25 kgf on the steering wheel rim can lead to slightly incorrect readings due to pumping by the hydrostatic steering motor. If the steering test is satisfactory, but the pressure readouts are different from those specified, the steering motor safety valve must be adjusted. The pressure readout should be: â&#x20AC;˘ Tractors with 4WD: 180 - 191 bar. 4. If the system pressure is not in accordance with the specifications, adjust it at the safety valve location on the steering motor. Use a hexagonal 8 mm spanner. Each half a turn of the screw is equivalent to approximately 14 bar. NOTE: To have access to the screw to adjust the pressure on the steering circuit it is necessary to remove the steering motor from the fixation support.

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Index Hydraulic systems - 35 Pump control valves - 102 Pump control valve Priority/Regulator valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Pump control valves - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Pump control valves - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Pump control valves - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump control valves - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Pump control valves - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pump control valves - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pump control valves - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Pump control valves - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Pump control valves - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 73403953 04/04/2014

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Hydraulic systems - 35 Combination pump units - 304

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Combination pump units - 304

TECHNICAL DATA Pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overview Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Pump Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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CONSUMABLES INDEX Consumable AMBRA MULTI G AMBRA MULTI G

Reference Pump - Assemble Pump - Install

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PAGE 35.4 / 20 35.4 / 24

Hydraulic systems - Combination pump units

Pump - General specification Tandem gear pump Main hydraulic pump â&#x20AC;&#x201C; Gear pump, fixed displacement Maximum flow at engine rotation speed of 2200 RPM New pump Used pump System relief valve activation Steering pump â&#x20AC;&#x201C; Gear pump, fixed displacement Maximum flow at engine rotation speed of 2200 RPM New pump Used pump

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49 l/min (13 US gpm) 44 l/min (12 US gpm) 176 - 182 bar (2552 - 2639 psi)

27 l/min (7 US gpm) 24 l/min (6 US gpm)

Hydraulic systems - Combination pump units

Pump - Exploded view Tandem gear pump - exploded view (front pump - hydraulic lift/remote valves/high pressure)

RCPH10TTS009GAD

Front pump internal components (1) Pump body (2) Rear plug (relief valve) (3) Filter support (4) Spring (relief valve) (5) Lower piston (relief valve) (6) O-ring (relief valve) (7) Body (relief valve) (8) O-ring (relief valve) (9) Backup ring (relief valve) (10) Driven gear (11) O-ring (transfer tube) (12) Backup spiral seal (transfer tube) (13) Transfer tube (long connector) (14) Woodruff cotter pin

(15) Hex bolt M10 x 1.5 x 115 mm (16) Hex bolt M10 x 1.5 x 110 mm (17) Grower washer 10 mm (18) Hex nut 1/2 in (19) Lock washer 1/2 in (20) Drive gear (21) Oil seal (22) Front pump cover plate (23) Hoop O-ring seal (24) Backup O-ring seal (25) Double bearing block (26) Drive gear shaft (27) Plug with O-ring (28) Elastic pin

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Hydraulic systems - Combination pump units

Tandem gear pump - exploded view (rear pump - steering/lubrication/low pressure)

RCPH10TTS008GAD

Rear pump internal components (1) Pump body (2) Backup spiral seal (transfer tube) (3) O-ring (transfer tube) (4) Transfer tube (short connector) (5) O-ring (6) Drive gear

(7) Rear pump cover plate (8) Hoop O-ring seal (9) Backup O-ring seal (10) Double bearing block (11) Driven gear (12) Spacer plate

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Hydraulic systems - Combination pump units

Pump - Sectional view Tandem gear pump (cross section view)

RCPH10TTS004GAD

Cross section of transmission mounted tandem gear pump (1) Outlet port to hydraulic lift (2) Steering pump drive gear (3) Steering pump driven gear (4) Outlet port to PTO (5) Hydraulic lift pump driven gear

(6) Hydraulic lift pump outlet port (7) Pump assembly drive gear (8) Hydraulic lift pump drive gear (9) Drive link (10) Pump inlet port (both pumps)

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Hydraulic systems - Combination pump units

Pump - Dynamic description The Fixed Flow Rate gear pump is installed on the righthand side at the rear, on the transmission, Figure Pump - Sectional view (35.304) The pump body contains two gear pumps assembled one behind the other (Figures 1 and 2).

RCPH10TTS045BAD

RCPH10TTS061BAD

The front pump, figure 2 (when installed on the tractor) supplies oil at high pressure to the three-point hydraulic lifter and to the remote control valves and is referred to as the hydraulic pump.

The rear pump, figure 2, called the steering pump, supplies oil to the hydrostatic steering system. The low-pressure circuits operate the power take off (PTO) and disconnect the auxiliary front wheel drive (AFWD). These circuits also supply lubrication to the PTO, Dual Power, bearings and output shafts. Regulation of pressure in the low-pressure system as well as securing of the lubrication circuit takes place in the TDF control valve housing valves. Both pumps share the same oil filter.

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Hydraulic systems - Combination pump units

Pump - Overview Pump operation The movement to the hydraulic lift pump (front pump) is transmitted through a gear located in the PTO clutch hub. A connection shaft between the two pumps transmits movement to the steering pump (rear pump), Figure 1.

RCPH10TTS004GAD

The gears inside both pumps move at the same speed and are driven while the engine is running. The two right toothed gear groups are mounted inside the pump on aluminum supports that incorporate steel bushings with porous bronze and PTFE lined with lead. The constant flow gear pumps are fed with oil from the reservoir in the center of the rear differential, through an intake tube installed in the pump intake orifice. When the engine is running, the PTO gear moves the pump and the oil is driven through the intake orifice, passing through the filter, to the spaces between the gear teeth inside each pumping unit. The oil is compressed between the gear teeth and the pump body is driven to the output orifices where it is unloaded in the hydraulic circuits. The hydraulic lift pump is protected from excessive pressure by a safety valve that operates at 190 bar. The valve allows the excess oil to return directly to the sump whenever there is any overload. This valve may be replaced without disassembling the tractor pump. The lubrication oil circulates directly from the PTO valve to the oil radiator before supplying lubrication pressure to the Dual Power.

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Hydraulic systems - Combination pump units

Pump - Prepare DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

1. Park the tractor on level ground. Turn the engine off. Chock the front and rear wheels. 2. Move the hydraulic controls back and forth a few times to release the pressure in the hydraulic lines. 3. Clean the area around the hydraulic oil drain plug as shown. Remove the drain plug and allow the oil to drain into an appropriate container. â&#x20AC;˘ On 2WD tractors, the oil is drained from the rear axle housing.

RCPH09TTS028AAD

RCPH09TTS040AAD

â&#x20AC;˘ On 4WD tractors, the oil is drained from the transfer case drain plug as shown. 4. After the oil has drained install the drain plug.

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Hydraulic systems - Combination pump units

5. Remove the right-hand side of the user platform floor. A. Remove the floor mat brackets (2) and bolt hardware. Lift the floor mat (1) off the platform. B. Remove the bolt hardware from the right-hand side of the platform (3). C. Remove the platform from the tractor.

RCPH10TTS044BAD

6. Be prepared to cap or plug disconnected hoses or ports to prevent oil contamination. NOTE: For easier access to the tandem pump; disconnect the brake actuating rods from the levers and remove the brake pedal linkage. Next operation: Pump - Remove (35.304)

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Hydraulic systems - Combination pump units

Pump - Remove DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump - Prepare (35.304) 1. Remove the filter guard (1), bolt hardware and support brackets (2). 2. Clean the area around the filter (3) and the tandem pump hose connections.

36083564

RCPH10TTS045BAD

3. Disconnect the pump as follows: A. Remove and discard the pump filter (1). B. Disconnect the tandem pump hydraulic hose connections. (2) – DualPower™ oil supply (3) – Steering motor oil return (4) – Steering motor oil supply NOTE: Limit oil contamination, plug and cap disconnected hoses.

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Hydraulic systems - Combination pump units

4. Remove the tandem pump's (1) six retaining bolts. 5. Remove the pump from the rear axle housing (1). 6. Remove and discard the pump gasket (2).

RCPH10TTS021AAD

Next operation: Pump - Install (35.304)

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Hydraulic systems - Combination pump units

Pump - Disassemble DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump - Remove (35.304) NOTE: When disassembling the pump, lay components out in the order of removal to facilitate a quick and easy reassembly. Perform the following procedure on a clean smooth surface. 1. Remove the pressure relief valve assembly, and discard O-rings and backup rings.

RCPH10TTS067BAD

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Hydraulic systems - Combination pump units

NOTE: If the pressure relief valve is not operating in accordance with specifications Pump - Pressure test (35.304), install a new seal ring.

RCPH10TTS020AAD

RCPH10TTS062BAD

RCPH10TTS063BAD

RCPH10TTS060BAD

2. Remove the nut (1), lock washer (2), drive gear (3), and woodruff key (4) from the drive gear shaft (5).

3. Remove all six front pump bolts and washers as shown.

4. Ease the cover plate (1) forward to clear the locating dowels (2). Tilt the cover to clear the transfer tube (3) and slide the cover plate off the pump housing.

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5. Slide the front pump gear shaft assembly out of the housing. NOTE: Take note of the bearing block identification markings while the pump gear is still assembled.

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6. Disassemble the front gear pump assembly. Discard O-ring, backup ring, and seals.

7. Disassemble the rear gear pump assembly. Discard O-ring, backup ring, and seals.

Next operation: Pump - Overhaul (35.304)

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Pump - Overhaul DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

NOTICE: Do not service gears, bearing blocks, or bushings as individual components but as matched sets. Replacing individual pump components may have an adverse affect on the tractor's hydraulic operations.

Prior operation: Pump - Disassemble (35.304) 1. Clean all components in a suitable solvent. Allow parts to dry. 2. Inspect bushings and bearing blocks for wear or damage. Check for blocked lubrication scrolls in the bushings. Replace the gears and bearing blocks as a matched set if required. 3. Inspect pump gears for wear or damage, particularly the bearing journals, gear teeth and side facings. 4. To ensure maximum pump efficiency, the width of each pair of pump gears must be within 0.005 mm (0.0002 in) of one another, and the journals within 0.013 mm (0.0005 in). 5. Remove light scoring marks on the gear facing areas using a sheet of "O" grade wet or dry abrasive paper and lubrication on a true flat surface. Polish the area repaired using light pressure in a rotating motion. Polished journals will achieve free movement in the body. 6. Inspect the gear track, embedded during the manufacturing process for the gear teeth, on the suction side of the pump. The track depth must not exceed 0.10 mm (0.004 in), or continue beyond the suction half of the gear aperture. Replace the pump when gear tracks do not fall within specification. 7. Burrs found at the edge of the gear track should be removed with "O" grade emery paper. 73403953 04/04/2014

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8. Inspect the pump cover for damage or cracks, particularly adjacent to the inlet and outlet ports, filter connection and pump face. Check internal passages for blockage. 9. Any component found unserviceable should necessitate replacing the pump assembly. If an emergency repair is required and worn components are replaced individually, note the following points: â&#x20AC;˘ The installation of new bearings will re-center the gears and prevent the tips of the gear teeth from bottoming, if continuing to use a pump body where the track is out of specifications. Pump inefficiencies will occur. â&#x20AC;˘ Under working conditions, hydraulic pressure within the pump loads the gears towards the inlet side of the pump body. Continued use of worn bearing and gear journals causes the gears to shift, thus further damaging the gear track in the pump body. Next operation: Pump - Assemble (35.304)

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Pump - Assemble DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump - Overhaul (35.304) NOTE: If required, refer to the Pump - Exploded view (35.304) for an overview of component placement. Or follow the component layout created during the disassemble procedure. NOTICE: Interchanging new, used, and original gears or bushings will adversely affect pump efficiency. When replacing components always replace in sets. Always replace O-rings, backup rings, and seals. 1. When replacing locating dowels, allow 2.54 mm (0.10 in) of the dowel to protrude from the pump housing (1).

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2. Assemble the transfer tube (1), seal (2) and o-ring (3). Insert them into the pump housing. • Install the longer transfer tube assembly on the front pump side of the housing. • Install the shorter transfer tube assembly on the rear pump side of the housing.

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3. Lubricate all internal components with clean 134D AMBRA MULTI G hydraulic oil. 4. Assemble the rear pump's original gears with original bearings. Do not switch components from their original orientation in the pump. If replacing components replace them in pairs not individually. • Place a new O-ring (1) and backup ring (2) on the rear pump's finished off edge bearing block (4). Only one of the two bearing blocks has a finished off edge. • Place the finished off edge of the bearing block into the rear pump housing (3) first. • Place the rear pump assembly over the transfer tube.

5. With new O-rings, back up rings, and seals; assemble the front pump gears and bearings.

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6. Slide the cover plate (1) over the drive gear axle (2). Rotate the cover plate over the transfer tube (4) and push the plate engaging both locating dowels (3).

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7. Secure the cover plate to the pump with bolts and washers. Use the following bolt placement information as a guide: • (1) – M10 x 110 mm dark black bolt • (2) – M10 x 110 mm knurled bolt • (3) – M10 x 115 mm knurled bolt • (4) – M10 x 115 mm dark black bolt • Tighten bolts to a torque of 50 - 62 N·m (37 - 46 lb ft).

8. If the pressure relief valve is not operating within specifications, install new a backup ring and O-rings on the pressure relief valve assembly.

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9. Secure the pressure relief valve assembly to the pump housing. Tighten to a torque of 60 - 68 N·m (44 - 50 lb ft).

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10. Insert the woodruff key (4) into the slot on the drive axle gear (5). Secure the assembly with the lock washer (2) and nut (1). Tighten nut to a torque of 50 - 55 N·m (37 - 41 lb ft).

Next operation: Pump - Install (35.304)

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Pump - Install DANGER Improper operation or service of this machine can result in an accident. Do not operate this machine or perform any lubrication, maintenance, or repair on it until you have read and understood the operation, lubrication, maintenance, and repair information. Failure to comply will result in death or serious injury. D0010A

Prior operation: Pump - Remove (35.304) NOTICE: Clean the area around the transmission opening to facilitate a tight seal between the tandem pump and the transmission. 1. Align the tandem pump's new gasket (1) over the transmission opening (2).

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2. Fill the pump's suction port (1) with clean 134D AMBRA MULTI G hydraulic oil and hand rotate the drive wheel (2).

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3. Install the pump assembly as follows: • Align the pump on the transmission over the mounting pin and the hydraulic inlet tube. • Confirm the pump drive gear correctly engages with the transmission idler gear. • Secure the pump to the transmission with six retaining bolts and washers. Tighten to a torque of 57 76 N·m (42 - 56 lb ft). 4. Remove hose caps or plugs and connect the pump. A. Connect the tandem pump hydraulic hose connections. (2) – DualPower™ oil supply (3) – Steering motor oil return (4) – Steering motor oil supply B. Attach a new pump filter (1). Clean the filter contact surface. Spread clean oil around the new filter rubber seal and install on the machine. Turn filter clockwise until both faces contact and then hand tighten 3/4 of an additional turn. Do not over tighten.

5. Secure the filter guard (2) to the support brackets (3) with the previously removed bolt hardware.

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6. Remove the filler plug (1). Fill with oil, checking the level with the dipstick (2). The oil level should be between the marks (3) on the dipstick. Maximum oil capacity: 66 l (17.4 US gal) 7. Start the engine to circulate the oil, extend all the cylinders and stop the engine. Check the oil level with the dipstick and if necessary, add new oil. Do not over fill. 8. Turn off the engine and check for leaks. NOTE: When operating remote cylinders, the rear axle oil level will be affected. When adding oil to the rear axle to accommodate the oil requirement of remote cylinders, no more than 45 l (11.9 US gal) should be added to bring the oil level up to within the marked area on the dipstick when all cylinders are fully extended. Alternatively, remote cylinders with the total oil capacity of up to 18 l (4.8 US gal) may be connected to the hydraulic system without adding oil, provided that the tractor is being operated on level ground. Next operation: Pump - Pressure test (35.304)

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Hydraulic systems - Combination pump units

Pump - Pressure test Prior operation: Pump - Install (35.304) Perform the following pressure and flow tests * Hydraulic main pump high pressure and flow test * Hydraulic steering pump pressure and flow test Low pressure circuit pressure test Lubrication circuit pressure test * If a suitable flow meter is not available for the recommended pressure and flow tests, use a 3000 psi pressure gauge and proceed to the "Alternate tandem pump pressure test". NOTE: It is important that the flow of oil returning from the steering motor to the tandem pump for redistribution to the low pressure and lubrication circuits, is regulated to the correct specification by the pressure regulating valve and lubrication circuit relief valve in the PTO assembly. It is, therefore, recommended that when pressure testing the pump the lubrication and low pressure circuit pressure tests are also performed.

Hydraulic main pump high pressure and flow test 1. Remove plug (1) from the pump outlet port.

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2. Install a suitable adapter (5) into the pump outlet port (6). 3. Attach a test hose (3) to an appropriate flow meter and the pump outlet adapter (4). 4. Connect a test hose from the flow meter's return port to the remote valve's upper port (1). 5. Move the corresponding remote valve control lever to the float position. 6. Open the load valve (2) on the flow meter completely. 7. Start engine and set speed to 2100 RPM. 8. Gradually close the load valve until a pressure reading of 137 bar (1987 psi) on the flow meter gauge is obtained. 9. Allow the engine to run until the hydraulic oil reaches a normal operating temperature not to exceed 75 Â°C (167 Â°F).

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10. Continue to close the load valve on the flow meter until the relief valve begins to react and pressure no longer increases, as observed on the flow meter gauge. The pressure reading must be between 176 - 182 bar (2552 - 2639 psi), and remain constant within 10% of the specified pressure until the relief fully opens, and pressure reduces to zero. NOTICE: Do not allow oil to exceed the maximum pressure of 182 bar (2639 psi) otherwise damage to the pump may occur. Remove and replace the pump's pressure relief valve if not within specifications and repeat the procedure. 11. If the relief valve operated correctly, open the load valve on the flow meter until a pressure reading of 166 bar (2407 psi), at 2100 RPM is obtained. Record the pump flow. 12. The minimum flow rate must be 49 l/min (13 US gpm) for a new pump. Overhaul the pump if not within specifications and repeat the procedure. NOTE: For tractors equipped with an auxiliary engine mounted hydraulic pump the flow rate at the remote valve should be 55 l/min (15 US gpm) for new pumps. If not within specifications remove the auxiliary pump [refer to Variable displacement pump - Prepare (35.106) for removal procedure] and test the tandem pump alone to determine which pump is not working properly and overhaul it. 13. Turn engine off, release pressure in the hydraulic lines, disconnect the flow meter, and install the pump outlet port plug. 14. Continue with the remaining pressure and flow tests. Refer to the "Hydraulic steering pump pressure and flow test" procedure.

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Hydraulic steering pump pressure and flow test NOTE: The flow meter for this test must be capable of withstanding back pressure of 21 bar (305 psi). 1. Disconnect the steering pump supply (1) and return (2) tubes. Cap or plug tubes.

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2. Install suitable test hose adapters (3) in the supply (4) and return (2) hose ports. Connect test hoses to the inlet and outlet ports on the flow meter. NOTICE: If the flow meter's load valve is closed, damage to the steering pump may occur. 3. Open the flow meter load valve (1). 4. Start the engine and adjust engine speed to 2100 RPM. 5. Slowly close the flow meter load valve until the pressure in the flow meter gauge reaches 137 bar (1987 psi). Do not allow pump pressure to exceed this value. 6. The minimum flow rate must be 27 l/min (7.1 US gpm) for a new pump or 24 l/min (6.3 US gpm) for a used pump. Overhaul the pump if not within specifications and repeat the procedure. 7. Turn engine off, release pressure in the hydraulic lines, disconnect the flow meter, and connect the steering pump supply (1) and return (2) hoses. 8. Continue with the remaining pressure tests. Refer to the "Low pressure circuit test" procedure.

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Low pressure circuit test 1. Disconnect the low pressure circuit fitting.

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2. Connect a suitable adapter (1), test hose (2), and a 300 psi pressure gauge (1) to the open circuit port. 3. Start the tractor and adjust the engine speed to 2100 RPM. Confirm the pressure gauge reading is between 200 â&#x20AC;&#x201C; 260 psi. Overhaul the pump if not within specifications and recheck. 4. Turn engine off, release pressure in the hydraulic lines, and remove pressure gauge assembly. Install the previously removed low pressure circuit fitting. 5. Continue with the remaining pressure tests. Refer to the "Lubrication circuit pressure test" procedure.

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Lubrication circuit pressure test 1. Start tractor and set engine speed to 1000 RPM. 2. Turn off the engine, do not adjust the throttle, and release pressure in the hydraulic lines. 3. Raise the engine hood and disconnect the oil cooler inlet hose (1). 4. Connect a suitable adapter (3), test hose (4), and a 300 psi pressure gauge (5) to the oil cooler inlet hose flange (1-2). NOTE: The connection between the oil cooler inlet house and the pressure test assembly must be tight for a safe and accurate pressure test. NOTICE: Allow the engine to run just long enough to take an accurate pressure reading, otherwise damage to hydraulic components may occur. It is recommended two people perform the next step to reduce the engine run time during the procedure. 5. Turn the engine ON. Check the pressure reading is between 77 â&#x20AC;&#x201C; 84 psi. Shut down the engine. 77 psi is the minimum operating pressure of the lubricating circuit relief valve.

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6. Release pressure in the hydraulic lines. Remove the pressure gauge assembly and connect the previously removed oil cooler inlet hose. 7. Tandem pump pressure and flow tests are now complete. Install the user platform, refer to the "User platform installation" procedure.

User platform installation 1. Install the right-hand side of the user platform floor. A. If applicable, reconnect the brake actuating rods between the levers and brake pedal linkage. See Brakes - Assemble (33.202) for the procedure. B. Align the platform on the tractor (1). C. Secure the platform in place with the previously removed bolt hardware. D. Place the floor mat (3) over the platform and secure it in place with the floor mat brackets (2) and bolt hardware.

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Alternate main hydraulic pump pressure test NOTE: Alternatively, if the tractor is not equipped with an engine mounted auxiliary pump attach the pressure gauge assembly directly to one of the remote valve's upper ports. 1. Remove plug (1) from the pump outlet port.

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2. Attach a suitable pressure gauge assembly (1â&#x20AC;&#x201C;5) to the pump outlet port. 3. Start engine and set speed to 2100 RPM. Take note of the pressure indicated on the gauge. 4. Reduce engine speed to 1200 RPM and check the pressure reading on the gauge. The pressure readings must be between 176 - 182 bar (2552 - 2639 psi) 5. Turn engine off, release pressure in the hydraulic lines, disconnect the gauge assembly, and install the pump outlet port plug. 6. Install the user platform, refer to the "User platform installation" procedure.

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Index Hydraulic systems - 35 Combination pump units - 304 Pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Pump - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pump - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Pump - Overview Pump operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pump - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Pump - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pump - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Hydraulic systems - 35 Remote control valves - 204

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Remote control valve Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Closed center mechanical remote valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Closed center mechanical remote valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

Couplers Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

SERVICE Remote control valve control lever Closed center mechanical remote valve - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Remote control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Remote control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Remote control valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

(*) See content for specific models 73403953 04/04/2014

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Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Closed center mechanical remote valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Closed center mechanical remote valve - Bleed Purging remote cylinders . . . . . . . . . . . . . . . . . . . . . . . . 56 Closed center mechanical remote valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Closed center mechanical remote valve - Service instruction Dual effect cylinders . . . . . . . . . . . . . . . . . 60

Couplers Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

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Remote control valve Closed center mechanical remote valve Torque Tightening values Desciption Flow control valve fixing thread Retainer valve rotary vane coupling Retainer valve casing fixing bolts Priority check valve Fixing studs between the valve housing and the coupler Fixation studs between the valve and assembling supports From the remote control valve coupler to the housing

kgm 2.7 kgm 0.7 kgm 0.7 kgm 0.7 kgm 1.5 kgm - 2.0 kgm 2.7 kgm - 3.5 kgm 8.2 kgm

Thread sealant Fastener and thread-locking sealant NEW HOLLAND, part number 82995773.

Remote control valve Closed center mechanical remote valve - Special tools Special tools Description

Tool No Purchase in local stores, in order to serve the flow indicator used. North America FNH00095 VL Churchill 8611

Flowmeter Flowmeter hose and connections Tool for Disassembling the Coupler Tool for Assembling the Slip Sealant

Remote control valve Closed center mechanical remote valve General specification Pressure Regulating Valve of the Retainer 148 - 162 bar (2146.0 - 2349.0 psi).

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Hydraulic connections and components Fig. 1 shows the installation of a dual remote control casing, in a tractor equipped with gear pumps. If necessary, up to four sets of remote control valves can be installed. When a tractor is equipped with gear hydraulic pumps, the set of priority valves that includes a sequence valve is also installed. The hydraulic elevator has priority over the oil flow pumped by the Hydraulic pump. Only the excess flow from the Hydraulic pump is diverted to the remote control through the sequence valve. When installed the auxiliary pump flow is let by external piping up to the priority valve set. The hydraulic pump oil flow is led by means of internal chambers up to the priority valve set.

LAIL11TS0218A0A

1. Inlet for Remote Control 4. Priority valve set (contains the sequence Valves valve) 2. Signal line 5. Remote Control Valve Body 6. Remote control valve 3. of Auxiliary pump, return Installed on Motor

All Tractors To guarantee that the pump flow is controlled by the remote control valve at the highest pressure of the circuit, priority retention valves are installed in the load sensor lines existent between each of the individual remote control valves. Where two, there or four individual sets of valves are installed, a retention valve will be installed at the T joint between the signal line of each valve. If there is a dual set of remote control valves installed, a retention valve will also be installed between the two valves items (22) and (23) in Remote control valve Closed center mechanical remote valve - Exploded view (35.204). The main components of the dual set of remote control valves are represented in Remote control valve Closed center mechanical remote valve - Exploded view (35.204), and should help to identify the parts and understand the oil flow diagrams. The individual parts of the simple set of remote control valves are identical to those that are represented in Remote control valve Closed center mechanical remote valve - Exploded view (35.204) for the dual valve.

Remote control valve Closed center mechanical remote valve General specification Retainer regulator valve 148 - 162 bar (2150 - 2350 psi).

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Torque Tightening values Desciption Flow Control Valve Fixation Thread Retainer Valve Rotary Vane Coupling Retainer Valve Casing Fixing Bolts Priority Anti-Return Valve Fixation Studs between the Valve and Coupler Casing Fixation Studs between the Valve and Assembling Supports From the Remote Control Valve Coupler to the Casing

kgm 2.7 kgm 0.7 kgm 0.7 kgm 0.7 kgm 1.5 - 2.0 kgm 2.7 - 3.5 kgm 8.2 kgm

Thread sealant Thread-locking Sealant NEW HOLLAND, Part No. 82995773

Remote control valve Closed center mechanical remote valve - Special tools Description Flow meter Flow meter hose and connections Tool for disassembling the coupler Tool for assembling the sliding seal

Tool No. Purchase in local stores for use with the particular flow indicator used North America FNH00095 VL Churchill 8611

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Hydraulic systems - Remote control valves

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Hydraulic systems - Remote control valves

Remote control valve - Detailed view Detailed view of a remote valve and attached components

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Hydraulic systems - Remote control valves

RCPH10TTS012GAD

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Hydraulic systems - Remote control valves

NOTE: Only one set of remote coupler components are shown for illustration purposes. (1) Hydraulic remote control levers (2) Control lever linkage (3) Hydraulic hose brackets (4) Remote valve support bracket (5) Hydraulic hose (6) Remote coupler assembly

(7) Remote valve assembly (8) Hydraulic oil fill tube assembly (9) Remote valve oil return tube (10) Remote valve oil pressure tube (11) Hydraulic tube sensor assembly (12) Priority control valve assembly

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Hydraulic systems - Remote control valves

Remote control valve - Exploded view

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Hydraulic systems - Remote control valves

RCPH10TTS011GAD

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Hydraulic systems - Remote control valves

(1) Spool (2) Screws (3) Spool retainer (4) Spool cleaner (5) O-ring (6) Shuttle check valve (7) O-ring (8) O-ring (9) O-ring (10) Plug (11) Backup ring (12) Washer (13) O-ring (14) Center spring retainer (15) Washer (16) Spool centering spring (17) Screw positioner (18) O-ring (19) Detent plunger (20) Flow control spool (21) Pin

(22) Plug (23) O-ring (24) Flow control bushing (25) Flow control knob with screw (26) Flow control end cap (27) O-ring (28) Spring (29) Plug (30) Plug (31) Plug (32) Plug (33) Primary check valve assembly (34) Flow restrictor bushing (35) Load check valve (36) Spring (37) Knob handle pin (38) Backup O-ring (39) O-ring (40) Backup O-ring (41) Retaining ring (42) Detent housing

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(43) Screws (44) Washer (45) Detent ball (46) Backup O-ring (47) O-ring (48) Backup O-ring (49) O-ring (50) End cap (51) Retaining ring (52) Regulator (53) O-ring (54) Restrictor (55) O-ring (56) Backup ring (57) Detent regulating valve (58) Spring (59) Detent valve spring adjuster (60) Lock nut (61) Detent piston (62) Detent piston spring (63) Ring

Hydraulic systems - Remote control valves

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Hydraulic systems - Remote control valves

Remote control valve - Dynamic description Single remote valve operation – Neutral

• A centering spring holds the control valve spool in neutral, blocking pump supply Gallery B. • The control valve spool also isolates Galleries G and H from pump supply Gallery B, and oil return Galleries E and F. This traps the hydraulic oil in both ends of the lift cylinder. • Galleries C and D connect with the return oil Galleries E and F, allowing pressure in the load sensing lines to return to sump. • The combining valve moves to the left, compressing the spring, and diverts oil flow from the pumps, back to the reservoir through the priority valve pack. – Pump pressurized oil – Trapped oil – Suction oil / return to deposit (1) Flow control restrictor (2) Load check valve (3) Check valve spring (4) Flow control knob (5) Detent regulating valve (6) Detent spool (7) Detent plunger and spring (8) Detent balls (9) Centering spring (10) External cylinder (11) Valve body

(12) Control valve spool (13) Shuttle check valve (14) Load sense line (pilot line) (15) Flow control spring (16) Flow control spool (17) Return to deposit (18) From auxiliary pump (if equipped) (19) Priority valve group (20) Supply to remote valve (21) Combining valve (22) Main pump supply

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Hydraulic systems - Remote control valves

RCPH10TTS009HAD

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Hydraulic systems - Remote control valves

Single remote control valve operation – Raising

• With the remote control valve lever in the raise position, the control valve spool moves forward and the springloaded detent balls engage the rear grooves of the detent plunger. • Pump supply Gallery B connects to Galleries G and D while Galleries H and C connect to return through Gallery E. • When initially moving the remote control valve lever, the pressure in Gallery D equalizes with the cylinder pressure, or the hydraulic back-pressure, whichever is greater. • The pressurized oil in Gallery D flows to the shuttle check valve and through an internal drilling to the detent regulating valve, flow control valve spool, and the pilot line (load sensing). • The pilot line (load sensing) pressure from Gallery D acts on the end of the combining valve spool, moving the spool to the right. The return Gallery in the priority valve pack closes and the main hydraulic and auxiliary pump (if equipped) oil pressure flows to the remote valve inlet port. • Pump pressurized oil flows from Gallery A to Gallery B through the flow control valve spool, flow control restrictor, and the load check valve. • The flow control restrictor setting (manually set with the flow control knob) determines the volume of oil entering Gallery B and flowing to Gallery G. • Exhaust oil from the cylinder Gallery H returns to the reservoir through Gallery E. • When the cylinder fully extends, pump supply pressure increases until the detent regulating valve opens. Pump pressurized oil moves the detent spool against the detent spring and releases the clamping effort on the detent balls at the end of the control valve spool. The centering spring now moves the spool back to the neutral position. • With the remote control valve lever in the raise position, the control valve spool moves forward and the springloaded detent balls engage the rear grooves in the detent plunger. – Pump pressurized oil – Suction oil / return to deposit (1) Flow control restrictor (2) Load check valve (3) Check valve spring (4) Flow control knob (5) Detent regulating valve (6) Detent spool (7) Detent plunger and spring (8) Detent balls (9) Centering spring (10) External cylinder (11) Valve body

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Hydraulic systems - Remote control valves

RCPH10TTS010HAD

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Hydraulic systems - Remote control valves

Single remote valve operation – Lowering with slow flow control setting

• Moving the remote control valve lever to the lowering position forces the control valve spool rearwards, allowing the spring loaded detent balls to engage the front groove on the detent plunger. • Gallery B connects to Galleries H and C, and Gallery G connects to Galleries D and F. This action reverses the connection to-and-from the cylinder. Pressurized oil retracts the remote cylinder in the same manner as described in the raising sequence. • The shuttle check valve enables the pilot line to sense pressure in Gallery C, and directs the flow of oil to operate the detent regulating valve and flow control valve spool. • The flow control restrictor rotates, reducing the slotted area in which oil flows into Gallery B and to the control valve, restricting oil flow to Gallery B. The degree of restriction, causes supply pressure to increase compared to pilot line pressure. • Pressure from the pump supply line, acts on the right hand end of the combining valve, and the spool moves against the spring, diverting surplus oil to sump. – Pump pressurized oil – Reduced oil flow – Suction oil / return to deposit (1) Flow control restrictor (2) Load check valve (3) Check valve spring (4) Flow control knob (5) Detent regulating valve (6) Detent spool (7) Detent plunger and spring (8) Detent balls (9) Centering spring (10) External cylinder (11) Valve body

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Hydraulic systems - Remote control valves

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Hydraulic systems - Remote control valves

Double remote valve operation

• Operation of two or more remote valves simultaneously, is possible irrespective of cylinder load. • When two spools simultaneously operate a light load and heavy load circuit, the oil flowing from the control valve attempts to flow to the light load circuit. The flow control spool maintains the set flow to the light load circuit. • The shuttle ball in the load sense line pushes firmly toward the low pressure circuit, isolating the line from the remote valve operating under the lighter load condition. • Hydraulic oil from pump supply Gallery B flows to the left side of the flow control valve spool through the shuttle check valve. Oil flows through radial holes in the spool at Gallery A to Gallery B. • When pressure differs greatly between two operating remote circuits, an excessive amount of oil flows from the pump supply Gallery B through the flow control valve, via the restrictor, to the remote circuit operating at the lower pressure. This additional flow results in increased pressure generated on the right-hand end of the flow control spool. • The flow control spool moves to the left and compresses the spring, progressively covering the radial holes in the spool. This restricts oil from Gallery A to the load check valve, and eliminates excessive oil flow to the light load circuit, while maintaining supply line pressure from the heavy load circuit. – Pump pressurized oil – Reduced oil flow – Suction oil / return to deposit – Controlled oil flow (1) Flow control restrictor (2) Load check valve (3) Check valve spring (4) Flow control knob (5) Detent regulating valve (6) Detent spool (7) Detent plunger and spring (8) Detent balls (9) Centering spring (10) External cylinder (11) Valve body

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Hydraulic systems - Remote control valves

RCPH10TTS013HAD

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Hydraulic systems - Remote control valves

Single remote valve operation – Float

• The float position allows operation of single acting cylinders when lowering under light load conditions. • With the remote control lever full forward in the float position, the control valve spool moves rearward past the lowering position to allow engagement of the detent balls with the grooves on the float detent plunger. • The control valve spool requires manual movement to neutral by the operator, as the shuttle check valve generates no pressure to release the detent mechanism. • Galleries E, F, G, and H connect to return, allowing the cylinder to float and assume any position. • Galleries C and D also connect to Galleries E and F, allowing only low back pressure on either side of the shuttle check valve. There is no pressure in the pilot line, and the pump output returns to the reservoir through the combining valve. – Pump pressurized oil – Trapped oil – Suction oil / return to deposit (1) Flow control restrictor (2) Load check valve (3) Check valve spring (4) Flow control knob (5) Detent regulating valve (6) Detent spool (7) Detent plunger and spring (8) Detent balls (9) Centering spring (10) External cylinder (11) Valve body

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Hydraulic systems - Remote control valves

RCPH10TTS012HAD

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Exploded view If there is a dual set of remote control valves installed, a retention valve will also be installed between the two valves items (22) and (23) in Fig. 1. The main components of the dual set of remote control valves are represented in Figure 1 and should help to identify the parts and understand the oil flow diagrams. The individual parts of the simple set of remote control valves are identical to those that are represented in Figure 1 for the dual valve.

LAIL11TS0006G0A

Fig. 1: Dual remote control valve

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Hydraulic systems - Remote control valves

1. Valve body 2. Remote control valve rods 3. Flow limiter (The flow limiter has to be installed with the large slit turned through relative to that of the illustration) 4. Load check valve 5. Flow limiter tip cover 6. Flow limiter control shaft 7. Flow limiter control button 8. Retainer rod 9. Centring spring of the control valve spool 10. Fixing nut 11. Retainer piston spring

12. Retainer piston 13. Detent valve spring adjuster 14. Nine retainer balls

15. Retainer regulator valve spring 16. Spacer 17. Automatic disarm valve spool 18. Retainer body 19. Hydraulic cylinder retainer valve 20. Flow control spring 21.Flow control rod 22. Priority retention valve ball (only with dual escape) 23. Priority retention valve fixer

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve - Overview 7630 8030

LA LA

Description and operation Description Tractors can be equipped with remote control valves, closed centre load sensors for external hydraulic applications. Up to four sets of remote control valves can be installed, Fig. 1. The valves are installed directly on fast opening couplers that are designed to allow flow without obstacles and low load loss. Each set of valves is activated by a lever located on the right side of the operator's seat, Fig. 2. The levers and their respective valves are identified by colours. The levers are moved forwards and backwards to extend, withdraw and float an external hydraulic cylinder.

LAIL11TS0550A0A

LAIL11TS0551A0A

The flotation function is selected when the lever is completely in the forward position. The floating position allows a coupled cylinder to extend or withdraw freely, just as a grader blade must follow the contour of the terrain. When pulling the lever back one stage the oil pressure leaves through the bottom coupler (lowering). When the lever is fully pulled back, the oil pressure is directed to the top coupler (lifting). Between the lowering and lifting positions, there is the neutral position.

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Hydraulic systems - Remote control valves

Automatic disarming: The automatic disarming system makes the control lever disarm when the equipment reaches the end of run and the hydraulic pressure in the system exceeds that adjusted by the retainer bolt. The lever does not disarm when it is in the floating position. To regulate the automatic disarm pressure turn the screw (3) in the clockwise direction to increase the pressure for disarm and anticlockwise to disarm more easily, Fig. 3. There is a conversion set available, in case the intention is to remove this retaining screw. NOTE: Never hold the lever in the extended or withdrawn position after the cylinder has attained its end of run, because this can cause the discharge valve to "explode", superheat the oil and damage the hydraulic components and transmission lines.

LAIL11TS0552A0A

LAIL11TS0553A0A

Each remote control valve has its own flow control valve (4) and a pair of couplers. The couplers are of a self sealing design and allow the implement hoses to remain loose when connected to the tractor. The top coupler (1) is identified by the symbol of an 'extended cylinder', moulded onto the rubber dust protection cover. The bottom cylinder (2) has the symbol of a 'retracted cylinder', Fig. 4.

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description Oil flow, with overload of the cylinder Under normal working conditions, the excessive pressures in the remote circuits are regulated by the automatic disarm mechanism, which moves the control valve rod to the neutral position when the external cylinder pressure becomes excessive or the cylinder attains its end of run. Nevertheless, if the operator annuls the detention and allows the pressure to become excessive, such as in an overload situation, the circuit is protected in the following manner: When the Hydraulic Lift is in lift and the remote control valves are being fed by the auxiliary pump installed in the motor, an excessive cylinder pressure, acting through the signal line, and the lowering orifice "H", opens the escape valve of the sequence valve, reducing the pressure acting on the left section of the valve. The sequence valve moves to the left, allowing the oil flow from the hydraulic and auxiliary pumps to return to the sump, limiting the maximum pressure of the remote control to 192 bar.

LAIL11TS0626G0A

Remote control hydraulic circuit in overload (single valve) 73403953 04/04/2014

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Hydraulic systems - Remote control valves

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

Flow control limiter Load check valve Check valve spring Flow control button Retainer regulator valve Retainer rod Retainer rod and spring Detainer bearings Centring spring External cylinder Valve body

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Control valve rod Non return valve Signal line Flow control spring Flow control rod Return to sump From auxiliary pump Hydraulic priority valves Control valve feed Sequence valve From main pump

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Hydraulic systems - Remote control valves

Remote control valve Closed center mechanical remote valve Dynamic description Oil flow in floating, with reference to Fig. 1 When the lever of the remote control valve is pushed completely forward, floating position, the rod is completely displaced backwards, to beyond the lowering position, to allow the retainer balls to seat in the retainer rod groove. When the control lever is in the floating position, the automatic disarm mechanism does not work and the rod will only return to the neutral position if the lever is activated. Orifice "G" for lifting and orifice "H" for lowering are connected with channels "F" and "E", allowing the remote cylinder to float and to assume any position. Channels "C" and "D" are also linked to the oil return channels "E" and "F", allowing only a low back pressure on both sides of the check valve. The load sensor line is therefore pressurized and the pump flow is discharged to the tank through the sequence valve.

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Hydraulic systems - Remote control valves

Remote control hydraulic circuit in floating (single valve)

LAIL11TS0600G0A

Oil pressurized to 190 bar 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Return to tank 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Control valve rod Non return valve Signal line Flow control spring Flow control rod Return to sump From auxiliary pump Hydraulic priority valves Control valve feed Sequence valve From main pump

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Retained oil

Hydraulic systems - Remote control valves

Couplers - Exploded view

RCPH10TTS013GAD

(1) Dust cover assembly (2) Left-hand coupler assembly (3) Right-hand coupler assembly (4) Retaining ring (5) Seal (6) Seal (7) Locking sleeve (8) Spring (9) Seal (10) Backup ring (11) Detent ball

Remote coupler components (12) Locking body (13) Retaining ring (14) Spring (15) Washer (16) Backup ring (17) Adaptor (18) Seal (19) Seal (20) Spring (21) Valve (22) Spring

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(23) (24) (25) (26) (27) (28) (29) (30) (31)

Probe O-ring Detent ball Sleeve O-ring Front sealing ring Retaining ring Spring Body

Hydraulic systems - Remote control valves

Couplers - Static description The remote couplers remain spring loaded to the closed position when disconnected from auxiliary hydraulic equipment.

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Hydraulic systems - Remote control valves

Couplers - Dynamic description With equipment connected and the remote valve pressurized, oil forces the hose connection check valve off the seat, while the spring-loaded probe remains in contact with the face of the check valve. Pressurized oil forces the locking sleeve within the coupler rearward, applying the locking balls against the end of the probe, preventing the probe from moving rearward. The probe locks in the forward position, which holds the connector check valve fully open, even under low-pressure conditions.

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Hydraulic systems - Remote control valves

Couplers - Sectional view

RCPH10TTS014HAD

Remote valve coupler oil flow (A) Coupler disconnected (not pressurized) (3) Hose connector check valve (B) Coupler connected (pressurized) (4) Probe (1) Coupler assembly (5) Locking sleeve (2) Auxiliary equipment hose connector (6) Detent balls

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Hydraulic systems - Remote control valves

Remote control valve control lever Closed center mechanical remote valve - Travel adjust Adjusting the cables 1. Place the control lever in the "Lifting" position and check whether the control valve rod (3) is completely out. 2. Loosen the nut (1) and move it away from the valve, sliding the external cable sleeve (2), until the cable clearance has been overridden. 3. Fasten the nut and check the valve functioning in all the positions.

LAIL11TS0132A0A

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Hydraulic systems - Remote control valves

Remote control valve - Remove WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

Prior operation: Remote control valve - Prepare (35.204) 1. Disconnect the remote valve (1) as follows: A. Disconnect the hydraulic hoses (2) from the top and rear of the remote valve. B. Cap or plug the hydraulic hoses or connectors. C. Disconnect the lever control linkage (3) from the back of the valve.

RCPH09TTS072AAD

2. Remove the remote valve as follows: A. Remove five Allen head bolts (1) located underneath and on both sides of the remote valve. B. Lift the valve off the remote coupler (2). C. Plug or cap any open ports on the remote coupler.

Next operation: Remote control valve - Install (35.204)

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Hydraulic systems - Remote control valves

Remote control valve - Disassemble WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

Prior operation: Remote control valve - Remove (35.204) NOTICE: Perform the following procedure on a clean smooth surface. 1. From the side of the valve housing, remove the priority check valve (1) and detent ball (3). Discard the O-rings (2).

RCPH10TTS055BAD

RCPH10TTS046BAD

2. From the back of the valve remove the flow control end cap (1) and discard the O-ring (2). Disassemble the spring (3) and flow control spool (4) from the rear of the valve.

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Hydraulic systems - Remote control valves

3. Remove the shuttle check valve (1). Discard O-rings (2) and (3), and backup ring (4).

RCPH10TTS054BAD

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Hydraulic systems - Remote control valves

RCPH10TTS014FAD

NOTE: In the following step the bushing can only be pushed into the housing approximately 1 mm (0.04 in), which is sufficient to allow removal of the retaining ring. Components called out in figures 4 and 5 are the same; use either as the need for clarity dictates. 4. Remove the remaining flow control components from the front of the valve housing. Proceed as follows: A. Loosen the control knob set screw (6). Remove the flow control knob (1). B. Push the flow control bushing (2) into the valve housing and with a suitable tool remove the retaining ring (3). C. Remove the internal components (2), (9), (10), (11), and (12). D. Discard O-rings, (4) and (7), and backup rings (5) and (8). RCPH10TTS047BAD

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Hydraulic systems - Remote control valves

RCPH10TTS015FAD

5. Disassemble detent assembly and detent regulating valve components. Proceed as follows: A.

Refer to figure 7 and remove three Allen bolts (17) and detent housing (1) from the end of the flow control spool (19). Discard the O-ring (18).

Refer to figure 6. Using a suitable press, push in the end-cap (9) sufficiently into the detent housing (1) and remove the retaining ring (10).

Refer to figure 6. Release the pressure from the end-cap, allowing the spring (11) within the detent housing to eject the end-cap.

Refer to figure 6. Remove the internal components (12) â&#x20AC;&#x201C; (16). Confirm all nine detent balls (15) are collected.

Refer to figure 6. Disassemble the detent regulating assembly (2), (3), (4), (5), (6), (7) and (8).

Refer to figure 6. Discard O-rings (3), (14) and backup rings (4), (13).

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Hydraulic systems - Remote control valves

RCPH10TTS016FAD

6. Refer to figure 8. Compress the centering spring (3) and remove the detent plunger (6) from the shaft (5). 7. Refer to figure 8. To prevent damage to the housing from the exposed end of the main spool (1), remove the spool from the opposite end of the housing. Remove and retain the washer (4) and both center spring retainers (2). 8. Repeat the procedure on the remaining valve assembly. 9. Clean all components in a suitable solvent and allow to dry before assembly. 10. Inspect all components for obvious damage, excessive wear or distorted spools and valves. Replace defective components. NOTE: The main spool, flow control spool and restrictor match the valve housing and are not available separately. Next operation: Remote control valve - Assemble (35.204)

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Hydraulic systems - Remote control valves

Remote control valve - Prepare WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

NOTICE: Contamination in the hydraulic system is a major cause of hydraulic component malfunction. Contamination is any foreign material in the hydraulic oil. Contamination can enter the hydraulic system in several ways: (A) Draining or filling the hydraulic reservoir. (B) Disconnecting hydraulic hoses or connectors. (C) Disassembling hydraulic components. (D) Damaged or worn seals. It is critical to work in a clean environment and thoroughly clean the area around any component that will be serviced. 1. Park the tractor on level ground. Turn the engine off. Chock the front and rear wheels. 2. Move the hydraulic controls back and forth a few times to release the pressure in the hydraulic lines. 3. Clean the area around the remote control valves. 4. If applicable, disconnect the external hydraulic equipment from the remote valves and remove it from the tractor. 5. Be prepared to cap or plug disconnected hoses to prevent excess fluid loss and/or oil contamination. Next operation: Remote control valve - Remove (35.204)

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Hydraulic systems - Remote control valves

Remote control valve - Assemble WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

Prior operation: Remote control valve - Disassemble (35.204) NOTE: Assemble the remote valve using the Remote control valve - Exploded view (35.204) as a guide. 1. Install a new O-ring into the detent valve channel in the valve housing as shown.

RCPH10TTS057BAD

RCPH10TTS058BAD

2. Place a new O-ring on the main spool. Insert the main spool through the back side of the valve as shown. Secure the back side of the main spool in place with a washer, retaining plate, and screws.

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Hydraulic systems - Remote control valves

3. Assemble the remaining main spool components as follows: A. Install new O-rings and backup rings over the main spool (1). B. Assemble the centering spring retainers (2), spring (3) and washer (4) over the main spool. C. Apply thread lock to the threads of the detent screw shaft (5). D. Compress the centering spring assembly and secure it in place with the screw shaft. Tighten to a torque of 7 NÂˇm (62 lb in).

RCPH10TTS017AAD

RCPH10TTS059BAD

RCPH10TTS016AAD

RCPH10TTS056BAD

4. Attach the detent plunger to the head of the screw shaft as shown.

5. Assemble detent assembly and detent regulating valve components as follows: A. Install new O-rings and backup rings. B. Assemble the detent regulating assembly. C. Install the internal components. D. Using a suitable press, push in end-cap sufficiently into the detent housing and install the retaining ring.

6. Place a new O-ring between the detent housing and the valve housing as shown. Secure the assembly to the valve with three Allen bolts. Tighten to a torque of 15 - 20 NÂˇm (133 - 177 lb in).

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7. On the side of the valve housing, install a check valve ball (3), new O-rings (2), and the priority check valve (1). Tighten to a torque of 7 NÂˇm (62 lb in).

RCPH10TTS055BAD

RCPH10TTS046BAD

RCPH10TTS015AAD

8. On the back side of the valve housing, assemble the spring, spool (1) and flow control end cap (2) along with a new O-ring (3).

9. Install the remaining flow control components from the front of the valve housing as follows: A. Install new O-rings and backup rings on the flow control bushing. B. Assemble the internal components. C. Push the flow control bushing into the valve housing and install the retaining ring. D. Attach the flow control knob and secure it with the set screw. 10. Install the shuttle check valve with new O-rings and backup rings.

RCPH10TTS054BAD

11. Repeat steps 1 through 10 for the remaining remote valve.

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Next operation: Remote control valve - Install (35.204)

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Remote control valve - Install WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you operate or service the machine. Failure to comply could result in death or serious injury. W0266A

Prior operation: Remote control valve - Remove (35.204)

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RCPH10TTS015GAD

NOTE: Only one remote coupler (1) is shown for illustration purposes. 1. Remove plugs or caps installed on the coupler during the removal procedure. 2. Replace O-rings between the valve (2) and coupler (1). 3. Position the remote valve on top of the coupler. Ensure the valve is seated properly. Secure the remote valve to the couplers with five Allen bolts (6). Tighten to a torque of 15 - 20 NÂˇm (133 - 177 lb in). 4. Remove caps or plugs from hydraulic hoses or connectors and replace worn O-rings, as needed. 5. Secure control linkage (4), hydraulic hoses/tubes (3), and hose bracket (5) to the remote valve (2). 6. Check the hydraulic oil level and fill as needed. Next operation: Remote control valve - Pressure test (35.204)

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Remote control valve - Pressure test WARNING Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in death or serious injury. W0178A

During the pressure test if any hydraulic leaks are noticed repair the leak and repeat the pressure test procedure. Prior operation: Remote control valve - Install (35.204) 1. Install the inlet hose of a suitable flow meter into the upper port of a remote coupler (1). 2. Set the corresponding flow control knob (3) to maximum flow. 3. Install the flow meter return hose into the lower port of the same remote coupler (2) on the tractor. 4. Fully open the load valve on flow meter. 5. Ensure all connections are secure. Start tractor and set engine speed to 2100 RPM. RCPH09TTS072AAD

RCIL10TTS001BAD

6. Position the same color remote control lever of the valve in float position, fully forward (1). 7. Position the remote control lever of the valve tested rearwards, to the extend position (2). 8. Gradually close the flow meter load valve until a pressure of 137 bar (1987 psi) is obtained. Allow the tractor to run until the hydraulic oil reaches an operating temperature near 75 Â°C (167 Â°F). 9. Continue to close the flow meter load valve, while observing a steady rise in pressure, until the detent regulating valve opens, at which point the needle on the flow meter gauge fluctuates, and the remote control lever returns to neutral. 10. The gauge reading immediately preceding needle fluctuation must be within 176 - 182 bar (2552 2639 psi) which is the pressure when the detent regulating valve must open. NOTE: The maximum flow capacity for a remote valve is 13.0 l/min (3.4 US gpm). If the tractor is equipped with an auxiliary engine mounted pump the maximum flow capacity is 15.0 l/min (4.0 US gpm).

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11.

For readings not within specifications, adjust the pressure as follows: A. Loosen the detent regulating valve locknut (1). B. Turn the adjusting screw (inside the valve locknut (1)) to change pressure. One-half turn (clockwise or counterclockwise) of the adjusting screw changes the pressure approximately 31 bar (450 psi). C. Tighten the detent regulating valve locknut. Repeat the pressure test RCPH09TTS072AAD

NOTICE: In the event the remote valve flow capacity is below specifications during maximum output, test the tandem gear pump pressure and if applicable the auxiliary pump pressure. The pumps may require repair.

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Remote control valve Closed center mechanical remote valve Pressure test Pressure tests The hydraulic pressure of the automatic disarm activator must be regulated when the valve set is serviced or when the control levers and rod prematurely return to neutral. Perform the test according to the following procedure, Refer to Fig. 1 . 1. Install the inlet tube of a flowmeter (4) in the top coupler of the set to be tested. Set the flow control lever (5) to maximum flow. 2. Install the flowmeter return tube (2) on the top coupler of the other group of remote control valves. 3. Completely open the flow meter load valve (3). 4. Run the engine at 1700 RPM. Put the lever of the valve assembly to which the flowmeter RETURN is coupled, in the FLOTATION position. Put the lever of the valve assembly to which the flowmeter INLET is coupled, in the LIFTING position. 5. Adjust the flowmeter load valve to a pressure of 140 bar and keep the engine running until a temperature of 75 °C is attained. 6. Gradually close the load valve and record the disarm pressure of the remote control lever. The disarm pressure should be between 148 - 162 bar. 7. To adjust the pressure: 8. Turn off the engine of the machine. • To INCREASE the pressure FASTEN the retainer screw (1). • To REDUCE the disarm pressure, LOOSEN the screw (1) by turning it in the anti-clockwise direction Each half a turn of the screw is equivalent to approximately 32 bar. NOTICE: Never adjust the retainer screw with the machine running.

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LAIL11TS0007F0A

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Remote control valve Closed center mechanical remote valve Bleed Purging remote cylinders 1. When a new cylinder with trapped air or a cylinder that has been out of service or had its hoses disconnected for a long time is fitted, the system will need bleeding in order to remove the air. With the hoses attached to the remote control valve couplers, place the cylinder with the hose side facing upwards and expand and contract the cylinder seven or eight times, using the control lever of the remote control valve. Check the rear axle oil level before and after operating a remote cylinder.

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Remote control valve Closed center mechanical remote valve Assemble Assembly Inspect all components for wear or other damage and replace all the sealing rings that have been removed. 1. Assemble following the opposite order of disassembly. 2. Lubricate the two new sealing rings and install them in the coupling cover slits. 3. Install new sliding seals placing them inside the retainers, Fig. 1. Set the seal in its position. 4. When available, insert Tool No. FT8611 (1) specifically for seating the sliding seal in the casing (2) and roll forwards and backwards. This operation lightly stretches and seats the seals so that the coupling can be installed.

LAIL11TS0130A0A

LAIL11TS0131A0A

5. Lightly lubricate the coupler and carefully install it in the casing. NOTE: Take greater case, as the coupler engages and makes the sliding seal expand. This circumstance is very important when no tool is available for installing the sliding seal. 6. Fasten the sleeve with a torque of 8.2 Kgf/m.

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Remote control valve Closed center mechanical remote valve - Disassemble Remote control valve coupler Disassembly 1. Unbolt the coupling from the tool described in Fig. 1 , unbolt the coupling. Introduce the part with the smaller diameter of the tangs of the fixation bolts from the tool into three of the circular holes existent in the external diameter of the coupler, and using a normal bench lathe, unbolt the coupler. Tool for Removing the Coupler: (1) Box measuring 30 mm welded inside item 2) (2) Sleeve (3) Tempered fixing bolt (3, in total) made of 60 mm bolts

LAIL11TS0128A0A

2. Disassemble the coupler, as shown in Fig. 2.

LAIL11TS0006F0A

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3. Remove the coupler cover (1) the two retainer rings (3) and the two slide seals (2), Fig. 3.

LAIL11TS0129A0A

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Remote control valve Closed center mechanical remote valve Service instruction Dual effect cylinders Connect the external piston feed hose (1) to the top coupler (4) and the return hose (2) to the bottom coupler (3) of the remote control valve assembly. Pull the remote control lever into the lifting position to activate the external hydraulic piston and push it into the lowering position to retract the piston. By positioning the lever fully forward, the external cylinder will be free to elongate and retract. Floatation is used for graders and loaders.

BRAG11TRCNH0152

BRAG11TRCNH0153

BRAG11TRCNH0154

Single-acting cylinders Connect the single-action cylinder hose (1) to the top coupler (2) of the remote control valve. To extend a cylinder, position the lever in the lifting position and to retract, place the lever in flotation.

To stop the cylinder, pull the lever into neutral or let it return by automatic disarming. Automatic disarming occurs when the piston reaches the end of run. The lowering position is meant only for dual action cylinders.

Continuous hydraulic flow equipment (hydraulic engines) Connect the hydraulic motor feed hose (2) to the bottom coupling (3) and the return hose (1) to the top coupling (4). Move the control lever on the control panel to the lowering position to activate the hydraulic motor and to the floating position to switch off the equipment. This procedure allows the equipment to lose inertia and prevents jerking.

For greater protection of the tractor and equipment, the following must be observed:

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1. Do not open any passage valve on the equipment or the engine. Use the flow adjustment valve to control the motor flow or speed. 2. Do not hold the remote control valve to make the equipment function. If the retainer does not hold the lever, adjust the retainer bolt (1), as described above and check whether the equipment is correctly tuned.

BRAG11TRCNH0155

3. To guarantee hydraulic oil optimum cooling and avoid overheating, activate the continuous flow equipment, adjust the maximum oil flow (using the flow control valve) and a lower motor speed that can provide the machine with the required behaviour and speed. 4. When hydraulic motors are used running continuously, it is recommendable whenever possible, to have a thermometer installed in the Remote Circuit. If any overheating occurs, cut the hydraulic motor until the oil cools down. Check whether the flow control is adjusted to maximum and whether the motor speed is at the minimum suitable for the machine performance. If the operating conditions are normal and the high temperature persists, install an oil radiator in return circuit to the engine. The recommended maximum oil temperature is 110 Â°C.

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Couplers - Disassemble 1. Unscrew the coupling from the tool described in Fig. 1, unscrew the coupling. Insert the smallest part of the shank on the tool mounting bolts into three of the circular holes in the exterior part of the coupling and, using a standard bench vice, unscrew the coupling.

LAIL11TS0128A0A

Figure 30: Tool for removing the coupling: 1. 30 mm box (welded on the inside of item (2)); 2. Sleeve; 3. Hardened mounting screw (3 in total) made from 6 mm screws

2. Remove the coupling, as per Fig. 2 ..

LAIL11TS0006F0A

3. Remove the two retaining rings (3) and the sliding seals (2) from the coupling casing (1), Fig. 3

LAIL11TS0129A0A

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Couplers - Assemble Inspect the components to see if they are worn or otherwise damaged and replace all the seal rings that have been removed.

LAIL11TS0130A0A

1. Fit the coupler in reverse order from removal. 2. Lubricate the two new seal rings and install them in the slots in the coupling casing. 3. Install new sliding seals and place them inside the retainers, Fig. 33. Check the seal is in the right position. 4. If there is one available, use a FT8611 (1) tool to seat the sliding seal in the casing (2) and roll it forwards and backwards. This operation lightly binds and secures the seals so the coupling can be fitted.

LAIL11TS0131A0A

5. Lubricate the coupling lightly and fit it, taking care with the cover. NOTE: Take great care to ensure that the coupling engages and the sliding seal expands. This is very important when the tool to install the sliding seal is not available. 6. Tighten the sleeve to a torque of 8,2 kgf.

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Index Hydraulic systems - 35 Remote control valves - 204 Couplers - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Couplers - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Couplers - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Couplers - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Couplers - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Couplers - Static description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Remote control valve - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Remote control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Remote control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Remote control valve - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remote control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remote control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remote control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Remote control valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Remote control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Remote control valve Closed center mechanical remote valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 30 Remote control valve Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Bleed Purging remote cylinders . . . . . . . . . . . . . 56 Remote control valve Closed center mechanical remote valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Remote control valve Closed center mechanical remote valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . 32 Remote control valve Closed center mechanical remote valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Remote control valve Closed center mechanical remote valve - General specification . . . . . . . . . . . . . . . . . . . . . . . 5 Remote control valve Closed center mechanical remote valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Remote control valve Closed center mechanical remote valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Remote control valve Closed center mechanical remote valve - Service instruction Dual effect cylinders . . . . . . 60 Remote control valve Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remote control valve Closed center mechanical remote valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remote control valve control lever Closed center mechanical remote valve - Travel adjust . . . . . . . . . . . . . . . . . . 38

(*) See content for specific models 73403953 04/04/2014

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Hydraulic systems - 35 Three-point hitch control valve - 114

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Three-point hitch control valve - 114

TECHNICAL DATA Hitch control valve Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Hitch control valve - Special tools Tool part number

Tool description Control valve bushing installation and removal tool kit Control valve bushing tool adapter Adapters and threaded rods: Special nut, extension, guide and adapter. Bush extractor and installer Template for Hydraulic Lift adjustment Template for Hydraulic Lift adjustment

FNH–02191 FNH–10090 NHT-0507 NHT-0506 NHT-0502 FNH-00014

Dealer fabricated tools Dealer fabricated tools are not provided, sold, or distributed from CNH America LLC. Use the following information as a guide to fabricate tools used to make adjustments and test the tractor's hydraulic components.

Control valve depth gauge NOTE: Previous tool part number FT8527 or FNH04654. Use a piece of steel with a thickness of 3.0 mm (0.12 in) and the following dimensions to create the hydraulic power lift control valve depth gauge tool. • Dimension A – 20.0 mm (0.79 in) • Dimension B – 11.7 mm (0.46 in) • Dimension C – 12.0 mm (0.47 in) RCPH10TTS011AAD

RCPH10TTS010AAD

Control Linkage Rod And Roller Setting Gauge NOTE: Previous tool part number FNH00014. Use a piece of steel with a thickness of 3.0 mm (0.12 in) and the following dimensions to create the control linkage rod and roller setting gauge tool. • Dimension A – 25.0 mm (0.98 in) • Dimension B – 72.0 mm (2.83 in) • Dimension C – 41.0 mm (1.61 in) • Dimension D – 6.0 mm (0.24 in) • Dimension E – 10.0 mm (0.39 in) • Dimension F – 6.0 mm (0.24 in) • Dimension G – 49.5 mm (1.95 in) • Dimension H – 0.76 mm (0.03 in)

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Hitch control valve - General specification Control valve sizes Valve color Orange Green Yellow Blue White

15.029 15.034 15.039 15.044 15.052

Dimensions – mm (inch) - 15.034 mm (0.5917 - 0.5919 in) - 15.039 mm (0.5919 - 0.5921 in) - 15.044 mm (0.5921 - 0.5923 in) - 15.052 mm (0.5923 - 0.5926 in) - 15.057 mm (0.5926 - 0.5928 in)

Control valve bushing sizes Valve color Green / White Orange Green Yellow Blue White Blue / White

Dimensions – mm (inch) 25.4 - 25.405 mm (1.0000 - 1.0002 in) 25.405 - 25.410 mm (1.0002 - 1.0004 in) 25.410 - 25.415 mm (1.0004 - 1.0006 in) 25.415 - 25.420 mm (1.0006 - 1.0008 in) 25.420 - 25.425 mm (1.0008 - 1.0010 in) 25.425 - 25.430 mm (1.0010 - 1.0012 in) 25.430 - 25.435 mm (1.0012 - 1.0014 in)

Auxiliary Service Control (ASC) valve sizes Valve color Blue / White White Blue Yellow Green

15.8293 15.8369 15.8445 15.8521 15.8598

Dimensions – mm (inch) - 15.8369 mm (0.6232 - 0.6235 in) - 15.8445 mm (0.6235 - 0.6238 in) - 15.8521 mm (0.6238 - 0.6241 in) - 15.8598 mm (0.6241 - 0.6244 in) - 15.8674 mm (0.6244 - 0.6247 in)

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Index Hydraulic systems - 35 Three-point hitch control valve - 114 Hitch control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hitch control valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Hydraulic systems - 35 Three-point hitch cylinder - 116

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hydraulic systems - 35 Three-point hitch cylinder - 116

FUNCTIONAL DATA Three-point hitch cylinder Three-point hitch cylinder - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Three-point hitch cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Three-point hitch cylinder Three-point hitch cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Three-point hitch cylinder - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Three-point hitch cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Three-point hitch cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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Three-point hitch cylinder - Overview The hydraulic top cover (1) provides a base for mounting the priority valve pack, brackets for the hydraulic lift control lever, draft control lever, and quadrant. In addition, the cover houses the top link sensing and draft control linkage system, hydraulic lift control linkage, lifting cylinder and arms, internal galleries, and covers the rear axle center casing hydraulic reservoir (2). The lift cylinder operates the lift arms to raise, lower and transport an implement. The lift cylinder assembly consists of a control valve, piston, exhaust valve, and a safety valve.

Lift cylinder exhaust valve RCPH10TTS004BAD

The spring-loaded exhaust valve, located in the lift cylinder, restricts the flow of exhaust oil from the lift cylinder, thereby maintaining the rate of drop for controlled lowering.

Lift cylinder safety valve The spring-loaded lift cylinder safety valve, located in the lift cylinder wall, protects the lift cylinder circuit from overloading, such as, when transporting implements over rough ground. The safety valve requires no servicing.

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Hydraulic top cover

RCPH10TTS002GAD

(1) Selector brace (2) Selector arm (3) Control valve tensor

(4) Control valve with brace and control roller. (5) Lifting cylinder (6) Position control brace

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Three-point hitch cylinder - Exploded view Lift cylinder component identification

RCPH10TTS005FAD

(1) (2) (3) (4) (5)

Lifting piston O-ring Stud bolts Ball Spring

(6) Detent plug (7) O-ring (8) Cylinder safety valve (9) Seal ring (10) Control valve sleeve

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(11) Deflector (diffuser) (12) O-ring (13) Exhaust valve (14) ASC (Auxiliary service control) valve (15) Lifting control valve

Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Disassemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Rear three-point hitch - Disassemble (37.110) NOTE: When disassembling the cylinder, lay components out in the order of removal to facilitate a quick and easy reassembly. Perform the following procedure on a clean smooth surface. 1. Disassemble the lift cylinder with reference to the Three-point hitch cylinder - Exploded view (35.116). 2. Insert a suitable tool (soft metal rod) through the safety valve bore to eject the lift cylinder piston. NOTE: The lift cylinder safety valve is not serviceable. 3. Disassemble the control valve.

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(1) Spool (2) Spring (3) Bolt

(4) Plate (5) Bushing

Next operation: Three-point hitch cylinder - Overhaul (35.116)

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Overhaul WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Three-point hitch cylinder - Disassemble (35.116) 1. Wash all parts in suitable cleaning solvent and allow the parts to dry. 2. Check oil passages for obstructions. 3. Examine valves and bore for wear, burrs or scratches. Remove minor damage to valve with fine emery cloth. 4. If the control valve bushing requires replacement, remove the bushing using tool FNH02191 or T8510 (1). The control valve bushing is color coded and the original size as fitted by the factory is indicated by a color spot on the cylinder casting adjacent to the control valve bore. Always install a new bushing with the same color code markings. When replacing the bushing, the bushing should be lubricated and drawn through the bore with either FNH02191 or T8510.

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(A) (1) (2) (3) (4) (5)

Bushing protrusion Tool FNH02191 or T8510 Control valve bushing Bushing centering guide FT8510–3 or FNH10090 Tool extension FT8510–A Guide adapter and cap, tool T8510–1K

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Hydraulic systems - Three-point hitch cylinder

5. When the bushing contacts the inner face of the guide, remove guide and continue to draw the bushing through the bore until the face of bushing protrudes 2.54 - 2.62 mm (0.100 - 0.103 in)beyond the rear face of the lift cylinder (A). 6. Ensure valves are thoroughly washed before assembly and move freely in bores. Heavy scoring of the ASC valve bore necessitates replacement of lift cylinder.

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7. When installing a new lift cylinder, select largest control valve and ASC valve spools, which when lightly lubricated, will operate in bore without binding when turned through 360 Â° and operated over full length of stroke. NOTE: The control valve bushing and ASC valve bores are color coded as a guide for matching the valve to the bore. To obtain an optimum fit, lap with locally available lapping compound. Ensure all traces of the lapping compound are washed away and dry all of the components before assembly. For valve sizes refer to Hitch control valve - General specification (35.114) for details. 8. If arm (2), piston rod (3) or retaining pins (1) and (4) are worn, separate rod and arm assembly. The pins are an interference fit into the arm, to remove pins use a suitable lever between rod and end face of pin.

Next operation: Three-point hitch cylinder - Assemble (35.116)

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Assemble WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Three-point hitch cylinder - Overhaul (35.116) NOTE: Assembly follows the disassembly procedures in reverse, with the following requirements. 1. Replace all O-rings and seals. 2. Install the O-ring (1) and backup seal (2) onto the lifting piston (3).

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3. To aid installation of piston (3) into lift cylinder and prevent damage to the piston seals, manufacture a guide to the dimensions.

(A) = 105 mm (4.134 in) (B) = 134 mm (5.276 in) (C) = 3 mm (0.118 in) (D) = 40 mm (1.575 in) (E) = 155 mm (6.102 in)

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Hydraulic systems - Three-point hitch cylinder

4. Install piston (1) into cylinder (3) using guide (2). Use a piston ring compressor if no guide is available and the piston is difficult to install.

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Next operation: Three-point hitch cylinder - Install (35.116)

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Hydraulic systems - Three-point hitch cylinder

Three-point hitch cylinder - Install Prior operation: Three-point hitch cylinder - Assemble (35.116) NOTE: The lift cylinder is an assembly of the hydraulic lift top cover; therefore refer to the Rear three-point hitch Assemble (37.110) section for more complete installation instructions. Ensure the lift cylinder retaining bolts are installed in the correct locations and torqued to 224 - 271 NÂˇm (165 200 lb ft)

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(1) (2) (3) (4)

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= = = =

76 mm 64 mm 57 mm 76 mm

(3.0 in) (2.5 in) (2.2 in) (3.0 in)

Index Hydraulic systems - 35 Three-point hitch cylinder - 116 Three-point hitch cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Three-point hitch cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Three-point hitch cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Three-point hitch cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Three-point hitch cylinder - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Three-point hitch cylinder - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Hitches, drawbars, and implement couplings

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

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CONSUMABLES INDEX Consumable Loctite® 518 Gasket Eliminator®

Reference Rear three-point hitch - Install

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Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

TECHNICAL DATA Rear three-point hitch Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Rear three-point hitch Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Rear three-point hitch Assemble Assembling the lift cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

DIAGNOSTIC Rear three-point hitch Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Rear lift arm Testing Excessive corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Testing Slow or no lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

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CONSUMABLES INDEX Consumable Loctite® 518 Gasket Eliminator®

Reference Rear three-point hitch - Install

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PAGE 37.1 / 40

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Torque Component Hydraulic lift cylinder to lift cover retaining bolts Hydraulic lift cylinder safety valve Hydraulic lift cover – Assembly to rear axle casing Hydraulic lift arm retaining nuts Hydraulic lift filler plug Control valve turnbuckle locknut Quadrant assembly to lift cover bolts Selector lever adjuster rod locknut Lift lever adjuster rod locknut Draft control nut set screw Position control adjusting screw locknut Yoke retaining nut set screw Priority valve pack to lift cover retaining bolts Detent shaft pivot coupling

Torque settings – N m (lb ft or lb in) 224 - 271 N·m (165 - 200 lb ft) 102 - 122 N·m (75 - 90 lb ft) 136 - 170 N·m (100 - 125 lb ft) 27 - 41 N·m (239 - 363 lb in) 50 N·m (37 lb ft) 14 N·m (124 lb in) 68 N·m (50 lb ft) 12 N·m (106 lb in) 12 N·m (106 lb in) 30 N·m (266 lb in) 24 N·m (212 lb in) 27 - 34 N·m (239 - 301 lb in) 57 - 76 N·m (42 - 56 lb ft) 7 N·m (62 lb in)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Weight Three point hitch load capacity Maximum lifting capacity on the three point hitch (maximum hydraulic pressure). Auxiliary Cylinder Without Auxiliary Cylinder: Hitch Eye* 610 mm ** 1 auxiliary cylinder Hitch Eye* 610 mm 2 auxiliary cylinders Hitch Eye* 610 mm

7630

8030

2880 kg 2227 kg

4250 kg 3211 kg

5579 kg 4273 kg

* Load applied to hitch eye; ** Load applied at a distance of 610 mm from the hydraulic lifting arm coupling eye.

Rear three-point hitch - Dimension Lift control valve spindle and sleeve measurements Color Orange Green Yellow Blue White Green/White Blue/White

15.057 15.052 15.044 15.039 15.034

Spool - 15.055 mm - 15.050 mm - 15.039 mm - 15.034 mm - 15.029 mm -

Cylinder safety valve opening pressure: 197 - 210 bar. Seal joint: No. 81865596.

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25.430 25.425 25.420 25.415 25.410 25.436 25.405

Liner - 25.425 mm - 25.420 mm - 25.415 mm - 25.410 mm - 25.405 mm - 25.430 mm - 25.400 mm

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Dynamic description The three-point hitch can operate in either draft control or position control. The control system selected depends on the type of implement in use and the operating conditions. A draft control lever and a position control lever, located on the right-hand side of the operator's seat, provide control of the hydraulic lift system.

Draft control lever The draft control lever (1) operates in a slotted bracket with formed notches to prevent accidental movement of the lever. To move the lever out of the notch, slide the lever to the right to clear the notches and move it to the desired position. A decal adjacent to the draft control lever clearly identifies the draft and position control settings. With the draft control lever in the forward notch (A), the three-point hitch is in the most sensitive setting and variations in soil density cause the hydraulic system to respond to small changes in soil condition. Move the draft control lever progressively rearward to decrease draft control sensitivity. The rearmost notch (B) positions the system in position control. NOTICE: Always set the draft control lever to position control in the rearmost notch when automatic correction of the three-point hitch is not desired, such as when attaching equipment, transporting equipment, or with no equipment attached.

Position control lever The position control lever (2) raises or lowers the threepoint hitch linkage and implement to the required height or working depth. Pushing the position control lever forward lowers the implement. Pulling the position control lever to the rear raises the implement. An adjustable stop (3) provides a means of returning the position control lever to the selected setting during use. To adjust the location of the stop, turn the knob counter-clockwise to loosen it and slide it to the desired position. Tighten the knob. The stop can be bypassed by easing the lever to the right to clear the stop.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Principles of draft control The draft control system manages the working depth of soil engaging implements to maintain an even pull on the tractor, and to reduce wheel slippage. When lowering a soil-engaging implement, e.g. a plow into the ground, the draft forces (A) applied to the implement tend to make the plow pivot at the point where it attaches to the lower links (B). Without the top link, the plow would tip up (C). Due to the top link resistance, the plow stays level in the ground. This creates a compressive force (1) acting on the top link against the tractor. The draft force will vary according to the depth of work and soil type. When draft forces increase beyond selection, the compressive force on the top link (1) pushes the yoke (3) further into the hydraulic lift cover and the three-point hitch raises the implement until the preset draft load is restored. When draft forces decrease below selection, the compressive force on the top link reduces, the yoke moves out from the top cover, and the three-point hitch responds by lowering the implement until the preset draft load is restored.

RCPH10TTS002FAD

Main forces applied by control linkage control (1) (2) (3)

Top link (compression) Lower link Draft control yoke

(A) (B) (C)

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Draft forces Pivot point of lower arm Rotational force

Hitches, drawbars, and implement couplings - Rear three-point hitch

Top link sensing and three-point linkage Draft forces applied to an implement, transmit mechanically from a rocker (1) and control yoke (2), to the draft control mechanism, via the top link (3) of the three-point linkage. The hydraulic system responds by raising or lowering the implement, to restore and maintain uniform draft loading.

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Draft control â&#x20AC;&#x201C; lowering The draft control lever (11) connects to the control arm (9) by a clevis link. As the control lever moves downward, the arm rises and aligns the control rod and roller assembly (5). The control rod and roller assembly attaches to the far end of the lever arm. The top pivot point of the control link (4) connects to the draft control main spring plunger (1). Downward movement of the lift control lever (10) moves the actuating lever (14) forward. The actuating lever pivots about the control rod connector (8) and allows the control valve spring (7) to move the control valve spool rearward into the lowering position. The lowering action stops, when the implement draft compresses the draft control main spring (2) in a forward direction enough to cause the main spring plunger to move the control link forward. This action causes the control rod to pivot the actuating lever about the top attaching point. The actuating lever overcomes the rearward pressure of the control valve spring and moves the control valve spool forward into the neutral position.

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Draft control â&#x20AC;&#x201C; lowering into work

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Draft control â&#x20AC;&#x201C; raising An increase in draft to the implement transmits through the yoke (3) to compress the draft control main spring (2), moving the draft control main spring plunger (1) in a forward direction. The control rod and roller assembly (5) connected to the plunger by the control link (4), pivots about the actuating lever (6). The actuating lever overcomes the pressure of the control valve spring (7), and moves the control valve spool forward, into the raise position. As the implement lifts, the draft forces acting on the yoke reduce, and the compression of the draft control main spring eases. The control valve spring moves the control valve spool rearward, back into the neutral position. A further decrease in draft reduces the draft control main spring compression and the pressure on the actuating lever. The control valve spring extends and moves the control valve spool, rearward into the lowering position. As the implement runs deeper, the draft increases and the control valve spool returns to the neutral position.

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Draft control â&#x20AC;&#x201C; raising

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Draft control â&#x20AC;&#x201C; transport position Pulling the draft control lever (10) to the top of the quadrant selects the transport position. The top of the actuating lever (12) pivots rearwards about the control rod connector, which allows the control valve spring (7) to move the control valve spool forward, into the raise position. To limit the height of the implement, the piston skirt contacts a stop pin attached to the actuating lever, when reaching the full raised position. The control valve spool moves rearward into the neutral position, stopping further movement of the lift piston. The stop pin functions in both draft and position control.

Principles of position control The system of position control enables the working depth or height of an implement, relative to the tractor, to be preset and maintained. During position control, the control rod and roller assembly (5) aligns with the lower end of the control link (4). With the control rod and roller in this position, any variations in draft loading applied to the yoke (3) through the top link and three-point linkage system will not alter the control rod and roller. Consequently, the actuating lever (12) and control valve (7) remain unchanged unless movement of the draft control lever (10) occurs. Moving of the lift control lever (11) pivots the control rod and repositions the control valve spool, to raise and lower the implement as required. As the lift arms move, the position control link (14) rides the position control cam (13), moving the control rod and actuating lever. With the lift arms in the desired position, the actuating lever returns the control valve to neutral, which stops further movement of the lift arms. Therefore, a direct relationship exists between the height of the lift arms and the position of the draft control lever.

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Position control linkage operation

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Assemble Assembling the lift cover 1. Apply sealant to the two sides of the joint. Application should be continuous around the entire face of the joint and with a thickness of approximately 1 mm; 2. Install the cover in the rear axle central housing and fasten the retaining bolts to 15.2 kgf ; 3. With the engine stopped, raise the lift arms by hand and check if they come down slowly by the action of their own weight. If this does not occur, re-check the torque applied on the arm fixing bolts; 4. Re-assemble the other components following the opposite order to that of disassembly.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Prepare WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine. Failure to comply could result in death or serious injury. W0138A

CAUTION Unexpected machine movement! When the machine is parked and the engine is switched off, the parking brake must be applied. Use wheel chocks if parking on a steep slope. Failure to comply could result in minor or moderate injury. C0014A

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Hitches, drawbars, and implement couplings - Rear three-point hitch

2. Lower the lift arms to their lowest position and take off the top link (3) and rocker arm (1).

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3. Lower the draft control lever until notches (3) and (4) are aligned. Tighten the 5/16 in UNC bolt (5) securing the notch alignment.

4. Clean the area around the hydraulic oil drain plug. Remove the drain plug and allow the oil to drain into an appropriate container. â&#x20AC;˘ On 2WD tractors, the oil is drained from the rear axle housing.

â&#x20AC;˘ On 4WD tractors, the oil is drained from the transfer case drain plug. 5. After the oil has drained install the drain plug.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

6. Be prepared to cap or plug disconnected hoses or ports to prevent oil contamination. Next operation: Rear three-point hitch - Remove (37.110)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Remove ATTENTION: Improper service or repair can cause injury or death. If you do not understand the service procedures for this machine, see your dealer or the Service manual. Failure to comply with these procedures can result in death or serious injury. ATTENTION: When handling lubricants (oil, grease etc.,) and other chemical products, always follow instructions for their proper use. Use proper containers to collect fluid. Dispose of fluids and filters in a way that will protect the environment and in accordance with the law. DO NOT smoke or use an open flame during the service procedure. Use eye protection. DO NOT handle engine coolant , engine oil or hydraulic oil at temperatures that exceed 49Â° C (120Â° F). Failure to comply will result death or serious injury. Prior operation: Rear three-point hitch - Prepare (37.110) 1. Disconnect the control lever linkage (2) and (3) from the hydraulic cover lever mechanism (1).

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2. Remove the remote valve from the hydraulic cover. Refer to Remote control valve - Remove (35.204) for further detail. 3. Disassemble the operator seat, PTO (lever, switch, and mechanism) and parking brake. A. Under the tractor operator platform disconnect the rear electrical harness connection to the seat connection. Remove the bolts securing the seat base to the platform. B. Disconnect the parking brake. Refer to Parking brake or parking lock - Disassemble (33.110) for further detail. C. Disconnect the PTO lever, switch, mechanism and spring support. NOTE: Tractor's equipped with an engine mounted auxiliary hydraulic pump and/or hydraulic ram cylinder(s), disconnect the metallic pipe on the priority control valve front port and the ram cylinder rod connection to the lifting arms. 4. Remove the seat, base plate, and bracket from the operator platform.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

5. If overhauling the lift cylinder loosen but do not remove the lift cylinder bolt hardware (1-4) before lifting the hydraulic cover off the rear axle housing. 6. If necessary remove the control valve (priority control valve) from the hydraulic cover. Refer to Pump control valves - Remove (35.102) for further detail.

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7. Remove the bolt hardware from around the perimeter of the hydraulic cover. With a suitable lifting device, lift the hydraulic cover (1) and slide it rearward exposing the rear axle housing (2). NOTICE: Do not let the hydraulic cover assembly rest on any of the internal components or controls.

Next operation: Rear three-point hitch - Disassemble (37.110) Next operation: Rear three-point hitch - Adjust (37.110)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Disassemble WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine. Failure to comply could result in death or serious injury. W0138A

Prior operation: Rear three-point hitch - Remove (37.110) 1. Disconnect and remove the hydraulic lift control valve tensioner. • Fork pin (1) • Tensioner (2) • Control valve (3) • Lever (brace part, roller, and control lever) (4) 2. Rotate the top cover so that it is upside down. 3. Remove the four bolts that secure the lift cylinder assembly to the lift cover. 4. Move lift arms to a raised position and carefully remove the lift cylinder from locating dowels. RCPH10TTS006BAD

NOTE: If overhauling the lift cylinder refer to Three-point hitch cylinder - Disassemble (35.116) for details.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

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Support linkage component identification (1) Bolt (2) Nut (3) Washers (spacers) (4) Set screw (5) Draft and position control adjustment plate

(6) Support plate (7) Roller and control brace axle (8) Selector lever (9) Open pin (10) Grommets (spacers)

Refer to Figure 2 and disassemble the support linkage components as follows: 1.

Loosen the lock nut (2) and remove the Belleville washers (3).

Remove the body (15) and the friction disc (14).

Remove bolt (4).

Remove the pivot pin of the housing (8) and remove the plate (5).

Remove three bolts (1) and remove the support (6).

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(11) Control brace and roller (12) Washers (spacers) (13) Gasket (14) Friction disc (15) Body

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Control arm, roller, and lever components (1) Shaft (2) Lever

(3) Arm (4) Brace and roller

Refer to Figure 3 and disassemble the control arm, roller , and lever components.

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(5) Washer (6) Detent

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Selector brace and eccentric shaft components (1) (2) (3) (4) (5)

Sleeve (bushing) Nut Brace Retaining ring Brace

(6) Retaining ring (7) Cam roller (8) Spacer (9) Retaining ring (10) Spacer

Remove the nut (2), washer (13), and bushing (1).

Remove the eccentric shaft (12) from the arm (5) and remove the spacer (10).

Remove the other end of the arm (3) from the cam (11) by removing the snap ring.

Remove the snap ring (6) and remove arm (3) from arm (5).

Remove the snap ring (9) and remove the cam roller (7) from the arm (5).

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(11) Cam (12) Eccentric shaft (13) Washer

Hitches, drawbars, and implement couplings - Rear three-point hitch

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

Disassemble the draft control main spring and plunger.

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Draft control main spring and plunger (1) (2) (3) (4) (5)

Retaining ring Plunger rod Washer Spring Washer

(6) Retainer nut (7) Detent seal (8) Fork (yoke) (9) Set screw (10) Support bracket

(11) Spring (12) Selector brace (13) Washer (14) Bolt (15) Washer

NOTE: The spring tension dissipates after the first couple of turns of the retaining nut (6). Refer to Figure 5 and disassemble the draft control main spring and plunger as follows: 1.

Remove the yoke (8) and the seal (7)

Remove the bolt (14) and the washer (15) Remove the selector arm (12) and the bracket (10).

Remove the retaining nut (6) and the plunger rod (2).

Remove the washers (3,5) and the spring (4).

Remove the plunger rod from the cover.

Remove the snap ring (1) and remove the selector arm (12) from the plunger rod.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

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Lifting arm components (1) Lift arm (2) Locking washer

(3) Bolt (4) Washer

Refer to Figure 6 and disassemble the lift arm components as follows: 1.

Remove the bolt (3) and washer (4).

Use a suitable puller and remove the lifting arms (1) from both sides.

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(5) Thrust washer

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Lifting arm rockshaft components (1) Bushing (sleeve) (2) Bushing (sleeve) (3) Detent seal

(4) Rockshaft (5) Piston rod and arm assembly (6) Bushing (sleeve)

Refer to Figure 7 and remove the rockshaft and components. Next operation: Rear three-point hitch - Assemble (37.110)

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(7) Bushing (sleeve) (8) Detent seal

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Assemble WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine. Failure to comply could result in death or serious injury. W0138A

Prior operation: Rear three-point hitch - Disassemble (37.110) Before assembly of the hitch components, note the following: • Replace any worn or damaged components. • Rotate the top cover to the inverted horizontal position. • Before installation of the rockshaft, coat the shaft and lip seals with grease. • The following torque procedure must be observed when tightening the lift arm retaining bolts.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

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Lifting arm and rockshaft components (1) Bushing (sleeve) (2) Bushing (sleeve) (3) Detent seal

(4) Rockshaft (5) Piston rod and arm assembly (6) Bushing (sleeve)

Refer to Figure 1 and install the rockshaft and components.

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(7) Bushing (sleeve) (8) Detent seal

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Lifting arm components (1) Lift arm (2) Locking washer

(3) Bolt (4) Washer

Refer to Figure 2 and assemble the lifts arms as follows: 1.

Install the lifting arm components on both sides.

Tighten the left hand arm retaining bolt to a torque of 27 - 40 NÂˇm (20 - 30 lb ft).

Lock the bolt in position with the tab washer.

Raise both lift arms and tighten the right hand arm retaining bolt sufficiently to allow the arms to lower under their own weight. Lock the bolt in position with the tab washer.

NOTICE: Do not over tighten bolts as damage to the rockshaft seals will occur.

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(5) Thrust washer

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Draft control main spring and plunger (1) (2) (3) (4) (5)

Retaining ring Plunger rod Washer Spring Washer

(6) Retainer nut (7) Detent seal (8) Fork (yoke) (9) Set screw (10) Support bracket

WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

Refer to Figure 3 and assemble the draft control main spring and plunger as follows: 1.

Prepare the plunger rod (2) sub assembly.

Install the selector brace (12) with the washer (13) onto the plunger rod (2) and secure with the retaining ring (1).

Coat the plunger rod with grease and Install the rod assembly into the hydraulic top cover.

Install the washer (3), the spring (4), and the washer (5) into the draft control spring bore.

Thread the retaining nut (6) into the housing.

Install the support bracket (10) with bolt (14) and washer (15). Torque the bolt to 40.7 - 54.2 NÂˇm (30 - 40 lb ft). Be sure to align the bolt with the machined area on the plunger rod.

Install the seal (7) and the yoke (8).

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(11) Spring (12) Selector brace (13) Washer (14) Bolt (15) Washer

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Selector brace and eccentric axle components (1) (2) (3) (4) (5)

Sleeve (bushing) Nut Arm Retaining ring Arm

(6) Retaining ring (7) Cam roller (8) Spacer (9) Retaining ring (10) Spacer

Refer to Figure 4 and assemble the selector arm and eccentric shaft components as follows: 1.

Install the cam roller (7) on the arm (5) with the spacer (8). Secure with retaining ring (9).

Assemble the arm (3) onto the arm (5) and secure with retaining ring (6).

Attach the other end of arm (3) to selector (11) and secure with retaining ring (4).

Install the eccentric shaft (12) through arm (5) and install spacer (10).

Install the washer (13), the bushing (1), and the nut (2).

Rotate the eccentric shaft (12) to locate the cam roller (7) in the highest position.

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(11) Cam (12) Eccentric shaft (13) Washer

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Control arm, roller, and lever components (1) Shaft (2) Lever

(3) Arm (4) Brace and roller

Refer to Figure 5 and assemble the control arm, roller, and lever components as follows: 1.

Insert the eccentric shaft (1) in the lever (2) and secure with a snap ring.

Install the washer (5) and the detent (6) on the shaft.

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(5) Washer (6) Detent

Hitches, drawbars, and implement couplings - Rear three-point hitch

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Support linkage component identification (1) Bolt (2) Nut (3) Washers (spacers) (4) Set screw (5) Draft and position control adjustment plate

(6) Support plate (7) Roller and control arm axle (8) Selector lever (9) Open pin (10) Grommets (spacers)

Assemble the hydraulic control linkage support.

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(11) Control arm and roller (12) Washers (spacers) (13) Gasket (14) Friction disc (15) Body

Hitches, drawbars, and implement couplings - Rear three-point hitch

Install the hydraulic lift cyliner 1. Lower the lift arms and carefully install the lift cylinder on the dowel pins. NOTE: If overhauling the lift cylinder refer to Three-point hitch cylinder - Disassemble (35.116) for details.

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2. From the top of the hydraulic cover, install the lift cylinder bolts. 3. Install and connect the hydraulic lift control valve. 1.

Fork pin (1)

Tensor (2)

Control valve (3)

Lever (brace part, roller, and control lever) (4)

Next operation: Rear three-point hitch - Adjust (37.110)

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Rear three-point hitch - Adjust WARNING Spring under tension! Compressed springs have potentially dangerous stored energy. Always assemble and disassemble properly. Failure to comply could result in death or serious injury. W0356A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Rear three-point hitch - Remove (37.110)

Adjustment and inspection setup 1. Position the hydraulic lift cover assembly on a support with the internal linkage facing upwards (as long as the priority valve pack is removed from the top of the cover), or vertically in a vice with the main draft spring end upward. 2. Ensure the assembly is not resting on the external control selector levers and the lift arms must move freely.

Internal control linkage inspection 1. Move the draft/position control lever (2) and the lift control lever (1) into random positions.

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2. At each setting manually move the lift arms (1) upward (lower position) and downward (raised position). 3. When moving the lift arm check the internal linkage cam roller (1), over travel spring (2), pivot block (3), and control valve spool (4)] for binding or other defects. Replace worn or damaged components.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

4. Place the lift arms (1) in the raised position (perpendicular with the top cover on the support). Rotate the lift control lever (2) counterclockwise to the fully raised position (lever at top of quadrant). This moves the control valve (3) spool inwards.

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5. Rotate the draft/position control lever back and forth while observing the travel of the roller (1) across the cam (2). 6. The roller must move square and parallel (2) with the cam and not at an angle (1) across the cam. 7. Replace any worn components, and proceed with the hydraulic lift internal control linkage adjustments. NOTICE: To ensure the proper operation of the hydraulic lift perform the following adjustment procedures (Main Draft Spring, Draft Control Linkage, Position Control Linkage) in sequence.

Main draft spring adjustment 1. Move the hydraulic lift arms (3) to the fully raised position (perpendicular to the top cover on the support). 2. Rotate the lift control lever (4) and the draft/position control lever (5) until the rod and roller (2) do not touch the cam (1). Ensure there is no tension on the control valve spool and spring (6). Check that the linkage is free to move. â&#x20AC;˘ Move the draft/position selector lever in the full position setting. â&#x20AC;˘ Move the lift/lower control lever in the full lowered setting.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Unscrew the yoke (6) from the plunger (2) and the top cover (1) to remove any previous preload. 4. Loosen the retainer nut setscrew (8) and turn the retainer nut (9) counterclockwise to create free-play in the main draft spring (4). Turn the retainer nut clockwise until free-play is eliminated (evident by feeling spring resistance).

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5. Screw the yoke (1) onto the plunger (should feel spring resistance). Turn the yoke the least amount necessary to position the hole in the yoke so it will be vertical when the hydraulic cover is reinstalled.

6. Verify the elimination of free-play with a small prybar (3) by prying on the main draft spring through the access hole (2). 7. Tighten the retainer nut setscrew (1) to a torque of 27 - 34 NÂˇm (20 - 25 lb ft).

Draft control linkage adjustment NOTE: Ensure the correct adjustment of the main draft spring is achieved before adjusting the draft control internal linkage. Refer to Hitch control valve - Special tools (35.114) for tool requirements.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

1. Move the lift arms (2) to the fully lowered position (parallel with the top cover on the support). 2. At the control lever side, check that the eccentric pin (1) rotated so lobe on inside of assembly points into the top of the assembly. If necessary, loosen the nuts on (1) and adjust the pin to obtain this position. NOTE: To ensure the hydraulic lift cylinder piston reaches the fully lowered position, remove the cylinder safety valve. Replace the safety valve after obtaining the fully lowered position.

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3. Place the position of the draft/position control adjustment plate (3) in draft control and move the lift lever until the notch on the body (2) is 1 mm (0.04 in) before the draft control notch (5) on the support. 4. Check for over-compression of the rod and roller overtravel spring (1), which is evident when a gap exists between the rod and roller pivot block and the washer. If the rod and roller spring is over-compressed, adjust the control valve spool turnbuckle (4).

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5. Gradually move the draft/position control lever (1), observing the control valve spool moves approximately 2 mm (0.079 in) into the control valve body (2). 6. Hand tighten the bolt (3) on the adjustment plate to temporarily secure this position.

7. Move the lift arms (1) between the raised position (perpendicular with the top cover) and the lowered position (parallel with the top cover) while observing for movement of the control valve spool (3), as it enters the valve body when raising and exits the valve body when lowering. â&#x20AC;˘ If the spool does not move, torque the nut (previously hand-tightened) to a torque of 20 - 29 NÂˇm (15 - 21 lb ft). â&#x20AC;˘ If the spool moves, gradually continue the process of resetting the draft/position adjustment plate until no further movement of the spool exists.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

8. Place the lift arms in the lowered position (parallel with the top cover). 9. Check that the rod (4) and roller (2) sits 48.5 - 50.5 mm (1.91 - 1.99 in) deep into the top cover with the control linkage rod and roller setting gauge tool (3). Place the edge of the handle flush with the machined surface of the top cover, measure down to the diagonal leg of the gauge tool dimension H 0.76 mm (0.03 in). NOTE: If the rod and roller is not within specification, repeat the Draft Control Linkage Adjustment from the beginning.

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10. With a scribe or similar tool, make a notch (1) in line with the draft control mark and the adjustment plate (2).

11. Remove the control valve faceplate on the opposite end of the control valve spool. 12. Place the control valve depth gauge (1) into the end of the control valve bushing (2).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

13. Check that the control valve spool (1) just touches the depth gauge – measured 11.7 mm (0.46 in) from the edge of the bushing (2) – dimension (A). If necessary, adjust the control valve spool turnbuckle until the end barely touches the gauge. Apply thread sealant to the turnbuckle threads and tighten lock nut to a torque of 163 N·m (120.2 lb ft).

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Position control linkage adjustment NOTE: Ensure the correct adjustment of the main draft spring and the draft control linkage is achieved before adjusting the position control internal linkage. Refer to Hitch control valve - Special tools (35.114) for tool requirements. 1. Move the lift arms (2) to the fully lowered position (parallel with the top cover on the support).

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2. Move the lift control lever until the body notch (2) is 1 mm (0.039 in) left of the notch (1) on the position control support.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Loosen the bolt and move the draft/position control adjustment plate (2) until its notch aligns with the scribe mark (1) that was made during the draft control linkage adjustment. Tighten the bolt (3).

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4. Use tool FT8527 to set the control rod to roller clearance. Place the edge of the tool flush with the machined surface of the top cover (3) and measure down to the diagonal leg of the gauge tool. Check that the rod (4) and roller (1) have a clearance of 0.76 mm (0.03 in) above the upper surface of the tool. NOTE: If the gap is not within specification, repeat the draft control linkage adjustment and the position control linkage adjustment from the beginning. If the measurement is correct, proceed with the adjustment procedure.

5. Remove the control valve faceplate on the opposite end of the control valve spool. 6. Place the control valve depth gauge (1) into the end of the control valve bushing (2).

7. Check that the control valve spool (1) just touches the depth gauge – measured 11.7 mm (0.46 in) from the edge of the bushing (2) – dimension (A). If necessary, adjust the control valve spool turnbuckle until the end barely touches the gauge. Apply thread sealant to the turnbuckle threads and tighten lock nut to a torque of 163 N·m (120.2 lb ft).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

8. If necessary, adjust the control valve spool by loosening the lock nut (1) and rotating the eccentric axle until the end barely touches the gauge. Tighten the lock nut to a torque of 20 - 27 NÂˇm (15 20 lb ft).

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Next operation: Rear three-point hitch - Install (37.110)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Install WARNING Improper operation or service of this machine can result in an accident. Read and understand the SAFETY INFORMATION Section before you perform any maintenance, service, or repairs. Read and understand the specific service procedures for the components you plan to work with before you start servicing the machine. Failure to comply could result in death or serious injury. W0138A

Prior operation: Rear three-point hitch - Remove (37.110) Before installation, note the following: • Replace any worn or damaged components. • Before installing the hydraulic top cover, apply a thin bead of LOCTITE® 518 GASKET ELIMINATOR ® to both sides of the new cover gasket. The bead must continue around the entire face of the gasket to a thickness of 1 mm (0.04 in) • Tighten top cover bolts to a torque of 136 - 170 N·m (100 - 125 lb ft) • Manually raise lift arms (engine not running and check that the arms fall slowly under their own weight. • Raise both lift arms and tighten the right hand arm retaining bolt sufficiently to allow the arms to lower under their own weight. Lock the bolt in position with the tab washer. NOTICE: Do not over tighten bolts as damage to the cross shaft seals will occur.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

1. Install the bolt hardware onto the perimeter of the hydraulic cover. With a suitable lifting device, lift the hydraulic cover (1) into place, covering the rear axle housing (2). NOTICE: Do not let the hydraulic cover assembly rest on any of the internal components or controls. 2. If necessary install the control valve (priority control valve) to the hydraulic cover. Refer to Pump control valves - Remove (35.102) for details.

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3. If overhauling the lift cylinder was necessary, install the lift cylinder bolt hardware (1-4) before lifting the hydraulic cover onto the rear axle housing.

4. Install the seat base plate and bracket onto the operator platform. 5. Assemble the operator seat, PTO (lever, switch, and mechanism) and parking brake. A. Under the tractor operator platform, connect the rear electrical harness connection to the seat connection. Install the bolts securing the seat base to the platform. B. Connect the parking brake. Refer to Parking brake or parking lock - Disassemble (33.110) for details. C. Connect the PTO lever, switch, mechanism and spring support. NOTE: For tractors equipped with an engine mounted auxiliary hydraulic pump and/or hydraulic ram cylinder(s), connect the metallic pipe on the priority control valve front port and the ram cylinder rod connection to the lifting arms. 6. Install the remote valve to the hydraulic cover. Refer to Remote control valve - Remove (35.204) for details. 7. Refill the hydraulic oil system, operate tractor hydraulic system and refill as required.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust Adjustment of the internal mechanism of levers Before making the adjustments, examine the internal mechanism of the levers, observing the following points: Move the lift/lower and position/effort levers and for each position, lift and lower the lift arms observing whether the internal articulation is free and that the components are not jammed. Put the lift arms in the lowering position and put the lift/lower lever in the raise position which will move the control lever inward. Move the position/effort lever forward and backward observing whether the roller movement is aligned with the cover. The roller articulation can be adjusted with shims. Do not put in too many shims and eliminate the lateral clearance of the roller. Adjust the alignment of the articulation, and if necessary, replace the used components.

Adjusting the dual action spring To adjust the dual action spring, proceed as follows: 1. Lifting/lowering lever completely lowered. 2. Fully raise the lift arms. 3. Place the position/effort lever in the first slot in position control. 4. Loosen the eyelet (6) to free any spring tension. 5. Loosen the locking plug (5). 6. Fasten the retaining nuts (7) until the play of the spring is eliminated. 7. Tighten the retaining nut plug (5) .

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8. Adjust the rod eyelet (6) until the play of the spring disappears. 9. Fasten the eyelet to a trestle with a hitch pin. If the eyelet is not in the horizontal position, turn it to the side that needs fewest turns to obtain alignment for the implement hitch pin to go through.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Adjusting the effort control rod 1. Ensure that the main spring is adjusted as previously described. 2. Remove the safety valve from the hydraulic lift cylinder. 3. Fully raise the lift arms. 4. Place the lift/lower lever in position (A) (Fig. 2: Position 'A' of the lever to adjust the hydraulic lift.) 5. Position/effort lever fully lowered (effort control). 6. With tool NHT-0502, adjust the measurement of 49.5 mm between the roller and the face of the hydraulic lift cover (Fig. 3: Adjust the height of the roller in relation to the edge of the cover: 1 Cam; 2. Roller; 3. NHT Tool; 4. Connecting rod) Tool NHT-0502 serves as a model.

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To adjust the measurement of 49.5 mm, loosen the retaining bolts and move the quadrant of the levers until the specification is reached. Re-fasten the fastening bolts on the lever quadrant.

7. Remove the front plate from the control valve. 8. Loosen the pressure nut and adjust the connecting rod until the valve is 11.7 mm from the external face of the sleeve. Tool FNH00014 serves as a template to adjust this measurement, Fig. 4: Adjust the position of the control valve in relation to the sleeve: 1. Tool FNH00014). 9. Tighten jam nut. Apply adhesive to the rod bolts.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Adjust the position control rod. 1. Fully raise the hydraulic lift arms. 2. Place the lift/lower lever in position "B" (Fig. 5: Position 'B' of the lever to adjust the hydraulic lift.) 3. Position/effort lever fully raised (position control). 4. With tool NHT-0502, adjust the measurement of 0.76 mm between the top face of the roller and the hydraulic lift cover (Fig. 6: Adjust the height of the roller in relation to the edge of the cover: 2. Roller; 3. NHT tool). Tool NHT-0502 serves as a model.

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To adjust the measurement of 0.76 mm, loosen the retaining bolts and move the quadrant of the levers until the specification is reached. 5. Re-fasten the fastening bolts of the lever quadrant.

6. Loosen the fastening nut and adjust the eccentric shaft bolt to attain a measurement of 11.7 mm between the external face of the sleeve and the control valve spool (Fig. 7: Adjust the position of the control valve in relation to the sleeve: 1. Tool FNH00014). Tool FNH00014 serves as template to adjust this measurement. 7. Tighten jam nut. Apply adhesive to the rod bolts.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Problem solving OPERATION Constant lift: • Check the control valve, sequence valve and outflow valve; Lifts or does not lift the equipment: • Excessive load (Problem of dimensioning the machine vs. the implement) • If the Remote Control valve is completely inside • If the valve connections are worn or jammed • The level and type of rear axle oil • Leaks and Oil filter • When the hydraulic (lift) works in control of position and does not work in draft control, the defect is probably in the lever connections. The converse is also true • The discharge valve and flow control valve jammed or scratched. TROUBLESHOOTING Corrections (Up/down): • This is related to oil leak in circuit components when the system is in neutral. Perform the following test: Lift the implement, pull the Remote Control lever and switch off the engine. NOTE: The hydraulic (lift) lowers: Piston broken, sealing rings, cylinder worn or broken, safety valve of the cylinder and Remote Control Valve. NOTE: The hydraulic (lift) does not lower: Sealing rings, sequence valve, Remote Control valve.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear lift arm - Testing Excessive corrections Test Point NÂ° 1 Condition Check Raise the implement to the maximum and stop the engine

Expected Result Result Arms do not lower Action A hydraulic fault does not occur Examine if the internal linkage is blocked or damaged Examine specially: Dial support Control roller and rod

Other Result (Possible Cause) Result Arms do lower Action A hydraulic fault does not occur Examine if the internal linkage is blocked or damaged Examine specially: Dial support Control roller and rod

Rear lift arm - Testing Slow or no lifting Test Point NÂ° 1 Condition In tractors with CCSC variable displacement hydraulic pump, a slow lifting can be produced if there is an excess of demand from the external hydraulic valves. A slow lifting in tractors with 16x16 transmission can be produced if the pedal clutch is depressed with an engine speed of less than 1000 RPM. Check Is CSA valve totally "in"?

Expected Result Other Result (Possible Cause) Action Result Is the external linkage blocked or Are external leaks observed? damaged? Action Is the external linkage blocked or damaged?

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Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110 Rear lift arm - Testing Excessive corrections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Rear lift arm - Testing Slow or no lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Rear three-point hitch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Rear three-point hitch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Rear three-point hitch - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Rear three-point hitch - Assemble Assembling the lift cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Rear three-point hitch - Dimension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Rear three-point hitch - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Rear three-point hitch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Rear three-point hitch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Rear three-point hitch - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Rear three-point hitch - Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Rear three-point hitch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Rear three-point hitch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Rear three-point hitch - Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Steering

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Steering - 41

[41.101] Steering control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.4

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CONSUMABLES INDEX Consumable Loctite® Loctite® 221 Loctite® 221

Reference Power steering pump - Disassemble Power steering pump - Assemble Power steering pump - Assemble

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Steering - 41 Steering control - 101

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Contents Steering - 41 Steering control - 101

FUNCTIONAL DATA Steering column Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - Steering control

Steering column - Exploded view

RCPH10TTS017HAD

(1) Steering column assembly (2) Steering wheel column (3) Steering cap (4) Lock nut

(5) Lock bolt (6) Pin (7) Collar clamp (8) Rubber insulator cushion

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(9) Bolt (10) Washer (11) Isolator cushion (12) Steering motor

Index Steering - 41 Steering control - 101 Steering column - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Steering - 41 Hydraulic control components - 200

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Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic control components Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

FUNCTIONAL DATA Hydraulic control components Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Power steering control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Power steering control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Hydraulic control components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic control components - Torque Torque values Steering and generalities Steering wheel fixing nut Front wheel nuts (with 4WD) Engine End Cover Outer hinge of cylinder to extension Outer hinge of cylinder to axle Cylinder ball joint clamps Cylinder ball joint nuts Extension tube from cylinder to cylinder Slope bolt from the column to the frame bolt Cylinder, tube end pin fixation bolt (with 4WD) 24.0

kgm 2.3 kgm 47.5 kgm 2.3 kgm 4.3 kgm 17.6 kgm 4.3 kgm 17.6 kgm 27.1 kgm 2.3 kgm 2.3 kgm

Nm 23 N·m 475 N·m 23 N·m 43 N·m 176 N·m 43 N·m 176 N·m 271 N·m 23 N·m 23 N·m

Hydraulic control components - Special tools Special tools Description Pressure manometer ( 400 bar) Roto-glyd seal installer Hose adaptor - manometer Test Hose Adapter (test hose to the tractor tube) 7/16 JIC Male x 9/16 JIC Male

NEW HOLLAND 380000240 380000281 83936707

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V.L.CHURCHILL FT 8503–A FT 8503–8

Steering - Hydraulic control components

Hydraulic control components - Calibration Description and operation The hydrostatic steering system is driven by oil pressure from the steering pump which is one of the pumping units of the main hydraulic pump installed on the rear axle of the tractor. The steering pump is responsible for supplying the Steering, Low Pressure (steering return) and lubrication circuits. The main hydraulic pump receives the force from the PTO intermediate gear and transmits it to the hydraulic pump gears. The hydraulic pump transmits the force to the steering pump gears via a drive shaft. The hydraulic and steering system pumps share the same oil entry chamber and the same filter. The steering pump pumps the oil to the hydrostatic steering motor which is driven by the steering column when the operator turns the tractor steering wheel. The pressurised oil in the steering motor drives the double action piston for tractors without 4WD (Auxiliary Front Wheel Drive). The steering motor is bolted to the steering column and connected to the steering column by a splined shaft and a lock pin. The steering column is adjustable at various tilt angles in all models. In wheel drive tractors, 2 steering cylinders are used, one for each wheel. The cylinders are fixed to the shaft housing and the trunnion eyes. The system pressure safety valve is inside the steering motor.

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Steering - Hydraulic control components

Schematic diagram of how the steering works - position in neutral

LAIL11TS0008F0A

1. Measuring valve

Pressure retention valve

2. Test valve

Control valve sleeve

3. Non return valve

Control Valve Spindle

4. Pump

10. Not available

5. Filter

11. Not available

6. Return via cooling and lubrication

12. Steering Cylinders

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Steering - Hydraulic control components

Operation The system is fully hydrostatic and as such there is no mechanical link between the steering column and the wheels. The oil flows from the rear axles to the pump by means of a filter, pressurised by turning the steering pump gear, and is expelled from the outlet gap in the pump to the steering motor. The oil received by the steering motor is sent to the drive cylinder when the tractor's steering wheel is moved. The steering motor includes a measuring unit that adjusts the volume of oil supplied to the cylinder so that it is proportional to the angular movement of the steering wheel. The measuring unit in combination with the test valve (item (2) - Fig. 1) allows the tractor to be driven even when there is no oil pressurised by the pump - manual steering.

Position in neutral With the steering wheel immobile, the centring springs align the spool and the sleeve in neutral when the steering is not activated. In this position, no oil is sent to the steering cylinders, Fig. 2. However, the oil retained is transferred between the sides of the left and right curves of the cylinders, enabling the wheels to react to the land, providing feedback to the driver.

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Steering - Hydraulic control components

Schematic diagram of how the steering works - steering activated

LAIL11TS0009F0A

Suction oil Top up steering motor Return oil High pressure oil (up to 170 bar) Measured oil to the steering piston

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Steering - Hydraulic control components

Turning to the right When the steering wheel is turned, the movement of the control valve fuse aligns a series of grooves in the sleeve When turned to the right, the oil flows via the sleeve with a groove in the valve spool into a path in the steering motor housing and then on to the measurement unit, Fig. 2. The measurement unit is activated by the rotor drive shaft and sends the oil through another series of paths in the spool, the sleeve and the steering cylinder. The return oil from the other end of the cylinder is sent from the spool and the valve sleeve to a return path in the housing. On turning the steering wheel to the left, the oil flows through the sleeve in a similar way as described for the right side.

Manual operation In the event of a steering pump fault or loss of oil pressure, the steering system can be set to work manually. When the machine's steering wheel is turned, the measurement unit rotor is also activated, forcing the oil into the steering cylinder. On the suction end of the measuring unit, the return oil flows from the cylinder and is aspirated through the safety valve to feed the measuring unit. When an extra supply of oil is needed, as occurs when turning to the left, the additional oil enters the hydraulic steering reservoir via the measurement unit safety valve.

Hydraulic control components - General specification Specifications Hydrostatic System:

Tractors with Auxiliary Front Wheel Drive (4WD) Pump Specifications Minimum Pump Output 31 l/min Steering motor displacement 150 with speed Maximum pressure of steering circuit safety valve: 170 bar Absolute pressure on manometer 180 - 190 bar (2610 - 2755 psi) Tractors with Auxiliary Front Wheel Drive (4WD) Maximum steering angle Steering turns (from lock to lock) Steering piston Curve radius: With 4WD brakes disconnected Without 4WD brakes disconnected Divergent

55 Â° 3,4 2 double-action pistons 3.45 m 4.04 m 13 mm

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Hydraulic control components - Overview Low pressure and lubrication circuit – 8 x 2 Models Fig. 1 shows the hydraulic schematic and the main components of the low pressure and lubrication circuit on TS6000 model machines with independent hydrostatic steering circuit. The circuit comprises one tandem pump pumping unit mounted on the rear tractor shaft. The rear pump (1) suctions the oil from the reservoir, passing through the filter (2) and pressurises it to a flow divider in the pump itself. The flow divider (3) directs the oil to the Power Take Off – PTO (4) and Auxiliary Front Wheel Drive – AFWD clutch set (5). The PTO clutch assembly has a valve to regulate the maximum pressure of the low pressure circuit (6) between 16.0 - 18.0 bar and another valve (7) to regulate the maximum pressure of the lubrication circuit between 6.0 - 8.0 bar. The lubrication circuit is formed by the excess pressure and flow rate from the low pressure circuit. It is represented by green lines in the lubrication diagram in Figure 1. The start circuit for the PTO clutch (4) passes the oil radiator (8) and then lubricates the transmission components (9). Maximum circuit pressure is regulated by valves (6) and (7) that release the excess pressure formed by the pump (1) to the reservoir. Pressure adjustment is to be done by adding shim washers to increase valve spring pressure. For details on the functioning of gear pump Rear electro-hydraulic control - Overview (31.104), Rear electro-hydraulic control - Overview (31.104), Rear electro-hydraulic control - Overview (31.104) and AFWD see Remote control valve Closed center mechanical remote valve - Overview (35.204), Mechanical transmission - Overview (21.114) .

LAIL11TS0684F0A

Low pressure and lubrication circuits hydraulic schematic on TS6000 line tractors with 8 x 2 transmission. Version with independent hydrostatic steering circuit.

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Hydraulic control components - Overview 7630 8030

LA LA

Hydrostatic steering, low pressure and lubrication circuit – models 8x2

LAIL11TS0482F0A

Hydrostatic steering, low pressure and lubrication circuits hydraulic schematic on TS 6000 line tractors with 8 x 2 transmission. Version with low pressure and lubrication circuit integrated to the hydrostatic steering circuit. Fig. 1 shows the hydraulic schematic and the main components of the hydrostatic steering, low pressure and lubrication circuit on TS6000 line tractors. This configuration integrates in the same circuit the three circuits mentioned above and uses the same hydraulic gear pump. The operating principle is similar to the hydraulic schematic with independent steering. The circuit comprises one tandem pump pumping unit mounted on the rear tractor shaft. The rear pump (1) suctions the oil from the reservoir, passing through the filter (2) and pressurises it to the steering motor (10). The steering motor oil return (10) follows on to the pump flow divider. The flow divider (3) directs the oil to the Power Take Off – PTO (4) and Auxiliary Front Wheel Drive – AFWD clutch set (5). The PTO clutch assembly adjusts the maximum pressure of the low pressure circuit (6) between 16.0 bar and 18.0 bar. The other valve (7) limits the maximum pressure of the lubrication circuit to between 6.0 bar and 8.0 bar. The lubrication circuit is formed by the excess pressure and flow rate from the low pressure circuit. It is represented by green lines in the lubrication diagram in Figure 1. The lubricating oil goes from the PTO (4) to the oil radiator (8) and to the transmission components (9).

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Hydraulic control components - Dynamic description Independent hydrostatic steering circuit Figure 1 shows the hydraulic schematic and main components of the independent hydrostatic steering. The circuit comprises a single gear pump (8) that supplies flow rate to the orbitrol (10). When the tractor steering wheel (1) is activated the orbitrol conducts (7) the oil to the steering cylinders (6). The hydraulic pressure in the circuit increases as the steering wheel gets closer to the end of travel. In normal operation the circuit will have high pressure peaks 172 bar (2500 psi) during manoeuvres. While the tractor is driven on a straight line, the steering motor (10) sends oil at low pressure to the radiator (5) to be cooled down. The oil at approximately 60 Â°C is taken to the reservoir (3) from where it is sucked in (4) by the pump (8). NOTE: The radiator must not be eliminated from the circuit as it ensures adequate working temperature.

LAIL11TS0493F0A

Independent hydrostatic steering circuit on TS6000 line tractors. 1. 2. 3. 4. 5.

Steering wheel Return line Steering oil reservoir Intake line Steering oil radiator

6. 7. 8. 9. 10.

Steering Cylinders Pressure lines Hydraulic gear pump Pressure line Orbitrol or steering motor

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Power steering control valve - Exploded view Steering motor - service

LAIL11TS0010F0A

Fig. 1 Expanded view of the hydrostatic steering motor 1. Valve spool lock pin 2. Centering springs 3. Fixing bolts 4. Guide Pin bolt 5. Sealing ring kit 6. Rear cover 7. Rotor and Stator set (measuring unit) 8. Collector plate 9. Rotor drive shaft 10.Test valve retainer screw

11. 12. 13. 14. 15. 16. 17. 18. 19.

Test valve ball Safety valve seat Safety valve seat components Safety valve spring Steering motor housing Reflux valve ball Reflux valve pin Rings and needle bearings Retention ring for springs (2).

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Power steering control valve - Remove Remove 1. Position the tractor on a level surface and apply the parking brake. 2. To have access to the steering motor, remove the right side protection cover from the motor. 3. Disconnect the four the steering motor supply/oil return tubes. Cover the ends of the tubes. 4. Remove the flexible fixation pin and the four bolts that fix the steering motor to the steering column, Fig. 1 (Orbitrol and oil piping fixing bolts.). 5. Remove the steering motor from the steering column. LAIL11TS0217A0A

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Steering - Hydraulic control components

Hydraulic control components - Troubleshooting Problem DIFFICULTY MOVING STEERING WHEEL

Possible Cause Damaged hydraulic pump

Correction Repair hydraulic pump

Leaks in counterbalance ball Oxidation of steering column bearings Damaged flow divider Leaks in steering cylinder Internal distribution cylinder seized up Stiffness of mechanical control

Install a new steel ball Replace steering cylinder detents Replace flow divider Replace steering cylinder detents Check and replace if necessary Lubricate steering levers or replace bushings Align steering unit and column

STEERING WHEEL Worn or broken leaf springs TURNS BY ITSELF STEERING WHEEL DOES Steering unit and column out of alignment Align steering unit and column NOT COME BACK TO NEUTRAL POSITION Jamming of valve cylinders Dismantle steering, find cause of problem and repair TOO MUCH PLAY IN Wear of rotor internal teeth Install a new rotor / stator assembly STEERING WHEEL Wear of shaft flange or tear of shaft Install a new drive shaft Worn or broken leaf springs Replace leaf springs Wear of drive shaft teeth Replace shaft and possibly rotor / stator STEERING WHEEL PLAY Air in steering cylinder Purge air from hydrostatic system and find VIBRATION cause of air entry Wear of mechanical control or of wheel Replace broken parts bearing Replace steering unit Broken flow divider Repair or replace steering cylinder STEERING WHEEL HAS Internal leaks in steering cylinder NO STOPS Excessive wear of rotor and stator Replace dosage unit (rotor and stator) Leaks between distribution cylinders and Replace steering unit between external cylinder and box ABRUPT REACTIONS OF Incorrect adjustment of drive shaft and rotor Adjust according to specifications STEERING WHEEL SLOW REACTION OF Lack of oil in system Check pump flow and speed. Replace flow STEERING divider or pump if necessary Replace steering unit Wear of steering unit STEERING WHEEL DOES Contamination of dosage cylinders Clean dosage unit or replace steering unit NOT COME BACK TO and clean hydraulic system NEUTRAL POSITION AND TURNS BY ITSELF Dosage cylinders seize up due to pressure Adjust pump pressure or replace flow diexcess vider if necessary INVERTED STEERING Improper connection of steering cylinder Install hoses properly hoses Incorrect adjustment of drive shaft and rotor Adjust properly Leaks in o-rings or loose screws Replace o-rings. Tighten screws according LEAKS IN COLUMN, to specifications (see torque values) DOSAGE UNIT, SAFETY VALVES OR CONNECTIONS Loose connections Tighten or replace connections Incorrect pump pressure LACK OF POWER OR Measure flow Replace divider if necessary STEERING IMBALANCE Internal leaks in steering unit Replace or repair steering unit

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Steering - Hydraulic control components

Hydraulic control components - Problem solving OPERATION Problems Possible Causes Without steering or heavy steering

Remedy

1. Air in the system.

1. Check for loose connections or damaged tubes. Drain air from the sys2. Steering circuit safety valve broken tem. or damaged. 2. Check system pressure. 3. Valve housing. 3. Check and repair. 4. Steering cylinder oil leakage. 5. Broken or damaged steering cylin- 4. Check and repair. der coupling. 5. Check and replace as required.

6. Steering motor worn or damaged. 6. Check and replace as required. Steering drifts (to the left or to the right). 1. Excessive clearance on the steering 1. Check and replace as required. connection joints. 2. Check and repair. 2. Leaks in steering cylinder. 3. Inspect and replace as required. 3. Steering motor worn or damaged. Front wheel oscillation when driving. 1. Leaks in steering cylinder. 1. Check and repair. 2. Steering motor worn or damaged.

TROUBLESHOOTING

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2. Check and replace the component when necessary.

Index Steering - 41 Hydraulic control components - 200 Hydraulic control components - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Hydraulic control components - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic control components - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Hydraulic control components - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic control components - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydraulic control components - Problem solving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic control components - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic control components - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic control components - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Power steering control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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Steering - 41 Pump - 206

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Steering - 41 Pump - 206

FUNCTIONAL DATA Power steering pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Power steering pump Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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CONSUMABLES INDEX Consumable Loctite® Loctite® 221 Loctite® 221

Reference Power steering pump - Disassemble Power steering pump - Assemble Power steering pump - Assemble

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PAGE 41.3 / 7 41.3 / 9 41.3 / 10

Steering - Pump

Power steering pump - Exploded view

TS6000PIC201

(1) Faceplate screws (2) (3) (4) (5)

Faceplate Screws Pin Detent washers**

(6) Cover (7) O-rings** (8) Stator (dosage unit) (9) Rotor (dosage unit) (10) Distributor ring (11) O-rings** (12) Spacing ring (13) Drive shaft (14) External cylinder*** (distribution valve)

(15) Internal cylinder*** (distribution valve) (16) Leaf spring (2 pieces) (17) Cross pin (18) Retaining ring (19) Bearing track (20) Thrust bearing (21) Bearing track (22) Spring pin (23) Bushing (24) Spring pin (25) Ball (2 pieces) (26) O-ring and thrust ring (27) Threaded bush (28) Ball

** Available as detent assembly *** Replace the whole steering assembly if one of these parts is defective

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(29) Box*** (30) Detent** (31) Plunger (pressure limiting valve) (32) Spring (pressure limiting valve) (33) Adjusting screw (pressure limiting valve) (34) Detent (pressure limiting valve) (35) Plug (pressure limiting valve) (36) Ball (safety valve) (37) Valve head (safety valve) (38) Spring (safety valve) (39) Adjusting screw (safety valve) (40) Detent (safety valve) (41) Plug (safety valve)

Steering - Pump

Power steering pump - Disassemble NOTICE: Never use a vice, as this could damage and destroy the steering motor. 1. Thoroughly clean exterior of steering motor and secure it to a suitable support device to disassemble. 2. Remove the seven screws from cover (A). NOTE: One of the screws is longer than the others because it has a spring pin. 3. Remove cover (A), rotor (C), stator (B), and spacing ring (E). Next, remove distributor ring (D), and drive shaft (F).

83087197

83087198

83087199

4. Tilt and shake steering unit (B) to remove the two safety valves (A).

5. Remove threaded bushing. Tilt and shake unit until the counterbalance valve ball (A) comes out.

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Steering - Pump

6. Push internal cylinder to remove internal and external distribution cylinders (A) together with the ball bearing and its tracks and the retaining ring. Check that cross pin is aligned between cylinders. Cross pin can be seen through the open end of internal cylinder.

83087200

83087201

83087202

83087203

7. Remove cross pin (A) from sliding set by pushing with the special screw with spring pin (B).

8. Carefully remove internal slider (C) and external slider (D).

9. Push leaf springs assembly (A) out of the internal slider (B).

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Steering - Pump

10. Use the appropriate tool to remove detent (A) from steering box.

83087204

83087205

NOTE: Remove safety valves only when it is strictly necessary. 11. Remove safety valve plug (A) and adjusting screw (E) with a 6 mm Allen wrench. Turn assembly over and shake it to remove springs with plunger (C) and ball (D). Do not remove valve seats as they are fastened with LOCTITEÂŽ .

A. Adjusting screw B. Ball C. Spring with plunger

83087206

NOTE: Dismount pressure limiting valve only when it is strictly necessary. These valves are regulated at a specified pressure.

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Steering - Pump

12. Remove valve plug (A) with an 8 mm Allen wrench. Remove adjusting screw with a screwdriver.

83087207

83087208

13. Turn assembly over and shake it to remove spring and plunger (C). Do not remove valve seat, as it is fastened with Loctite.

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Steering - Pump

Power steering pump - Assemble WARNING Flying debris! Wear eye protection and protective clothing during the cleaning process. Clear the area of bystanders. Failure to comply could result in death or serious injury. W0364A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Power steering pump - Disassemble (41.206) Before carrying out mounting procedure, wash all parts again with a solvent (oil-based preferably) and let dry on residue-free absorbent paper. NOTICE: Never dry with cloths or cotton. 1. Install valve plunger (A) with a pair of tweezers. 2. Put spring (B) in the hole over the piston. 3. Apply LOCTITEÂŽ 221 over the thread of adjusting screw (C) of the pressure limiting valve. Tighten the screw (C) until spring starts to tighten. 4. Install detent on its seat. Place plug (D) over it and tighten to a torque of 40 - 60 NÂˇm (30 - 44 lb ft).

RCPH10TTS094BAD

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Steering - Pump

5. With a pair of tweezers, put balls (A) in their housing. 6. Apply vaseline to the spring and mount it on valve head. Put springs (B) with valve heads (C) in its corresponding housings. 7. Apply LOCTITEÂŽ 221 to the adjusting spring (D).Tighten the screw until spring is under pressure. 8. Install detents in their housings and place plug (E). Tighten to a torque of 30 - 40 NÂˇm (22 - 30 lb ft) to plug.

RCPH10TTS095BAD

83087211

TS6000PIC205

9. Slide internal cylinder (B) into the interior of external cylinder (A), aligning the grooves (C) of leaf springs of both cylinders.

10. Arrange the both straight leaf springs (A) on the outside of the four curved leaf springs (B) as shown.

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Steering - Pump

11. Insert a suitable tool (A) through the slotted openings on the cylinders. With the tool collapse the leaf spring assembly (B) and pull the assembly through the distribution valve (cylinder) assembly (C). Avoid tilting the tool (leaf spring ends should not protrude).

83087212

83087214

83087215

83087216

12. Insert cross pin (A) in distribution valve assembly (B).

13. Mount and install as mentioned: retaining ring (A), track (B), thrust bearing (C) and track (D). NOTE: The slanted edge of the track (B) shall be oriented towards the internal track of the valve.

14. Place a new detent (A) inside the housing (B) with sealing rim outwards, and put detent on groove with an appropriate tappet.

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Steering - Pump

15. Apply grease on rings (E) and install onto an appropriate sized plunger (A).

83087217

16. Push the appropriate sized sleeve tool (C) until it meets the bottom of steering valve box (D). 17. Push the big plunger (B) with the small plunger (A) until they reach the bottom of the sleeve tool (C). NOTE: The small plunger remains inside the box until installation of distribution valve. 18. Remove `sleeve tool (C) together with the big plunger (B) of the box (D).

83087218

83087219

83087220

19. Coat the distribution valve (A) in clean oil. Turn the valve while inserting it into housing (B). NOTICE: Confirm the cross pin is in a horizontal position inside the housing.

20. Put ball (A) in its housing. Screw bushings (B) into the housing until resistance is found. Bushing should not protrude from box surface.

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Steering - Pump

21. Install both counterbalance valve assemblies (A) with balls into the corresponding housings.

83087221

83087222

83087223

83087224

22. Insert o-ring (A) in the housing (B).

23. Mount distributor ring (A) so that the disc holes match the holes of the box. Place drive shaft (B) on box side, with the groove in vertical position. Hold drive shaft (B) with an suitable tool.

24. Install rotor (A) on drive shaft (B) so that rotor hole is placed on drive shaft groove as illustrated. NOTE: Figure shows mounting position of rotor and shaft. It must be mounted this way even if drive shaft groove and cross pin are not visible.

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Steering - Pump

25. Rotor (A) and cross pin (B) must be in the specified position. NOTICE: It is essential that cross pin is in specified position for proper steering operation

83087225

83087226

83087227

26. Place spacing ring (A) as shown.

27. Place bolt with spring pin (C) in the appropriate hole. Secure cover (A) with remaining bolts (B). Tighten to a torque of 30 - 35 NÂˇm (22 - 26 lb ft).

Next operation: Power steering pump - Pressure test (41.206)

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Steering - Pump

Power steering pump - Pressure test WARNING Pressurized system! Never disconnect or tighten a hose or tube that is under pressure. If in doubt, engage the controls several times with the engine switched off prior to disconnecting or tightening the hose or tube. Failure to comply could result in death or serious injury. W0998A

Since valves are integrated, it is not possible to test steering once it is installed. Adjustment of pressure limiting valve and safety valves is only possible when steering unit is dismantled and always on the test bench. Use BOSCH injectors checker to verify valves operation. Connect checker to steering unit with a seeder steering hose with adapter KDJ10113. Connect return to injectors checker reservoir with a plastic tube. Fill checker with clean hydraulic oil. Prior operation: Power steering pump - Assemble (41.206) (A) (B) (C) (D)

BOSCH injectors checker Pressure hose Adaptor KJD10113 Return plastic tube

(E) Suitable plug (1) Steering unit (4) Return connection (5) Pressure connection

1. Connect hose (B) to pressure connection (5) and return tube (D) to connection (4). 2. Block both connections to the steering cylinder (to turn to the right and left) with suitable stoppers. 3. Turn steering to its full capacity to the right or left using a 5/8â&#x20AC;? duct adaptor and keep it in this position. Pump lever (A) for pressure to rise. If adjustment of safety valves is appropriate, pressure should not exceed 105 bar (1523 psi), nor be lower than 100 bar (1450 psi).

83087228

83087229

Pressure limiting valve adjustment 1. Pressure in the pump (A) is regulated with a valve screw (B). 2. Remove stopper and adjust the valve screw. Turn counterclockwise to increase pressure and clockwise to reduce pressure. Once valve is adjusted, check working pressure with the injectors checker. When pressure is correct, place plug and apply 40 - 60 NÂˇm (30 - 44 lb ft).

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Steering - Pump

Relief valve test (A) (B) (C) (D)

BOSCH Pressure Tester Pressure hose Adaptor KJD10113 Return plastic tube

(1) Steering unit (2) Steering cylinder connection (counterclockwise turn) (3) Steering cylinder connection (clockwise turn) (4) Return connection

1. Safety valves must be checked first. Connect hose (B) to connection (3) of steering cylinder (clockwise turn). Connect plastic tube (D) to return connection (4). 2. Pump lever (A) to increase the pressure. Pressure should increase to 150 - 165 bar (2175 - 2393 psi). Repeat operation to check counterclockwise turns of safety valve connecting hose (B) to steering cylinder connection (2) turn counterclockwise).

83087230

83087231

Relief valve adjustment 1. Adjust safety valve pressure by turning screws (B) and (C). Remove plugs first. Turn screw clockwise with a 6 mm Allen wrench to increase pressure, or counterclockwise to reduce it. Once adjustment has been made, check valve working pressure again.

2. When pressure is correct, place plug and tighten to a torque of 30 - 40 NÂˇm (22 - 30 lb ft).

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Steering - Pump

Power steering pump - Flow test Steering circuit pressure test When the hydrostatic steering system is working, the oil pressure (1) supplied by the steering pump to the steering motor may rise to the maximum pressure of the steering motor safety valve, which is 70 bar. The return from the steering motor (2) goes by means of external piping to the main hydraulic pump (Fig. 1).

LAIL11TS0133A0A

LAIL11TS0134A0A

The oil flow that leaves the steering motor returns to the pump body to be distributed by the low pressure and lubrication circuits. The pressure of the oil returning from the steering motor is regulated to a pressure of 16 - 18 bar by the low pressure regulating valve in the clutch assembly of the P.T.O. at 2100 RPM. As the pressure is regulated, the excess oil in the low pressure circuit flows through the regulating valve to the lubrication circuit that limits the oil pressure in the lubrication circuit to 5.0 - 8.0 bar to 4.5 l/min

Steering pump There is no safety valve in the steering pump. The following practical test will determine whether the pressure generated by the pump is sufficient to adequately run the steering system.

Steering Test 1. Engine speed adjusted to 1000 RPM. 2. Turn the steering wheel rapidly from lock to lock (Fig. 2). Evaluate whether the steering is functioning correctly, and that there is no delay between turning the steering wheel and the movement of the wheels. When the steering is at the end of run, one should hear the safety valve in the steering motor relieve the excess pressure to the tank and the speed of the motor should slow down to approximately 970 RPM.

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Index Steering - 41 Pump - 206 Power steering pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Power steering pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Power steering pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Power steering pump - Flow test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Power steering pump - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Steering - 41 Cylinders - 216

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Steering cylinder Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Steering cylinder Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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Steering - Cylinders

Steering cylinder - Exploded view

RCPH10TTS018GAD

(1) Steering cylinder main assembly (2) Articulating ball joint (3) Ball joint (4) Nut (5) Bolt

(7) Packing and detent seal (8) Steering cylinder housing (9) Piston rod (10) Cylinder head cover plate (11) Piston detent expander O-ring and seal assembly

(6) Hydraulic fitting with O-ring

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Steering - Cylinders

Steering cylinder - Exploded view Steering cylinder assembly

LAIL11TS0007G0A

1. 2. 3. 4. 5. 6. 7. 8. 9.

Piston and conrod assembly Cylinder Extension tube End of conrod link Anti-dust ring Clamp bolt Cable tie Nut Seal ring kit*

10. Nut 11. End of conrod link 12. Clamp bolt

* The seal ring kit consists of: • Conrod and bush seal rings • Piston sealing ring • Bush seal ring

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Steering - Cylinders

Steering cylinder assembly - four wheel drive

LAIL11TS0012F0A

1. 2. 3. 4.

Cylinder Wiper seal Locking ring Seal nut

5. 6. 7. 8.

Cylinder conrod Bush and seal assembly Piston Nut

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Steering - Cylinders

Steering cylinder - Overview Installing the steering cylinder - Four Wheel Drive.

LAIL11TS0597F0A

1. 2. 3.

Articulated pin Articulated pin D washer

4. 5. 6.

Spacer Spacer Locking ring

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Steering - Cylinders

Steering cylinder - Disassemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

NOTE: Steering cylinder should be removed if differential housing support is going to be removed. It will not be necessary to remove it from its support if you are trying to solve an oil leak problem in the cylinder. 1. Loosen the cylinder to differential housing four bolts by two turns counterclockwise. 2. Turn the steering wheel counterclockwise, thus releasing cover and differential housing cylinder. A small oil leak through the cover may occur. 3. Disconnect right and left ball joints of steering arms. 4. Release braces from steering cylinder ball joints and then release cylinder ball joints. NOTE: These connections are very tight so, to loosen them, they need to be grasped firmly and loosened with high-quality tools. 5. Disconnect and cap hydraulic hoses from the cylinder housing. Remove the four bolts and cover plate from cylinder housing. 6. Remove piston rod. 7. Remove rings, o-ring and piston detent, cover detent and packing on the side of cylinder cover and on right end. Refer to the Steering cylinder - Exploded view (41.216) for details. NOTE: Cylinder and rod cannot be replaced separately. If any of these parts are damaged, replace the cylinder and rod as a set. 8. Replace ball joints if worn. Next operation: Steering cylinder - Assemble (41.216)

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Steering - Cylinders

Steering cylinder - Assemble Prior operation: Steering cylinder - Disassemble (41.216) 1. Replace all O-rings and seals. Refer to the Steering cylinder - Exploded view (41.216) for details. NOTE: Cylinder and rod cannot be replaced separately. If any of these parts are damaged, replace the cylinder and rod as a set. 2. Clean parts in a suitable oil based solvent and allow parts to dry before assembling. Inspect and replace worn or damaged components. 3. Install rings, o-ring and piston detent, cover detent and packing on the side of cylinder cover and on right end. Refer to the Steering cylinder - Exploded view (41.216) for details. NOTE: Cylinder and rod cannot be replaced separately. If any of these parts are damaged, replace the cylinder and rod as a set. 4. Replace ball joints if worn. 5. Install piston rod. 6. Connect and cap hydraulic hoses to the cylinder housing. 7. Tighten the four cylinder cover plate bolts to a torque of 120 NÂˇm (89 lb ft)

NOTE: Steering cylinder should be removed if differential housing support is going to be removed. It will not be necessary to remove it from its support if you are trying to solve an oil leak problem in the cylinder. 8. Release braces from steering cylinder ball joints and then release cylinder ball joints. NOTE: These connections are very tight so, to loosen them, they need to be grasped firmly and loosened with high-quality tools. 9. Connect right and left ball joints of steering arms.

NOTE: Steering cylinder should be removed if differential housing support is going to be removed. It will not be necessary to remove it from its support if you are trying to solve an oil leak problem in the cylinder. 10. Turn the steering wheel clockwise, thus securing cover and differential housing cylinder. A small oil leak through the cover may occur. 11. Tighten the cylinder to differential housing four bolts by two turns clockwise.

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Steering - Cylinders

Steering cylinder - Remove Removal 1. Place the tractor on a level surface and leave the wheels aligned forwards. 2. Disconnect the flexible tubes, cover the open ends of the tubes. NOTE: The flexible hose position and the joint directions must be the same when reassembling. 3. Remove the retaining nuts (3) and separate the ball joints (1) from the connecting rod (2), Fig. 1.

LAIL11TS0136A0A

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Steering - Cylinders

Steering cylinder - Install Installing 1. Assembly of the steering cylinder and the track control connecting rods is done in the reverse order to that of disassembly. 2. Bolt the ball joint of the anchor extremity to the extension tube. Unscrew the ball joint a fraction of one turn and make sure that the joints are well positioned, as in Fig. 1. Fasten with a torque of 4.4 Kgf/m.

LAIL11TS0143A0A

LAIL11TS0144A0A

LAIL11TS0145A0A

3. Compress the cylinder connecting rod until the piston touches the bottom of the cylinder. 4. Install the ball joint of the anchor extremity to the connecting rod/track shaft, Fig. 2 and fasten with 18.0 Kgf/m. 5. Position the right wheel with the steering wheel turned to the right to the maximum. 6. Lengthen the cylinder connecting rod from the completely compressed position by 4.0 - 10.0 mm.

7. Adjust the piston connecting rod ball joint to align with the track connecting rod saddle. Install the joint (1), Fig. 2, and fasten to 18.0 Kgf/m. 8. Position all the wheels aligned forwards, adjust the track connecting rod to reach a divergence of 0 13.0 mm measured on the wheel rim at the height of the cover ( (A) minus (B)), Fig. 3. 9. Eliminate the air from the system switching on the motor and turning the wheels from lock to lock several times. Repeat until the steering works correctly.

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Steering - Cylinders

Steering cylinder - Assemble Reassembly 1. Install new piston sealing rings (4) and wear segments (1) in the piston (2), Steering cylinder - Inspect (41.216). 2. Install new sealing rings (3) in the bushes, make sure that the sealing lip is facing forward in the direction of the oil pressure. Install the new supporting segments (5), sealing ring (4) and connecting rod cleaners (2), Fig. 1.

LAIL11TS0140A0A

LAIL11TS0141A0A

LAIL11TS0142A0A

3. Lubricate the sealing ring and slide the bushing assembly (2) into the piston connecting rod (1), Fig 2. NOTE: It requires special care to install the piston sealing ring on top of segment 'O'. Allow the sealing ring to contract naturally before installing the piston and connecting rod assembly in the cylinder.

4. Place the cylinder barrel (3) in the vertical position and introduce the piston/connecting rod and bushing assembly, Fig. 3. 5. Bolt the bushing to the barrel until it is well seated.

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Steering - Cylinders

Steering cylinder - Disassemble Disassembly 1. Drain all the oil from the cylinder and cover the ends. 2. Loosen the clamp bolts (1) and remove the ball joint assemblies (2), Fig. 1. 3. Install the appropriate adaptations to the cylinder orifices to fix it in a vise. NOTICE: Do not fasten directly around the cylinder, as the assembly may be damaged.

LAIL11TS0137A0A

LAIL11TS0138A0A

4. With a "C" screwdriver (2), unscrew the extension tube (1) and the bushing assembly, Fig. 2. 5. Remove the bushing and the piston/connecting rod assembly from the cylinder. 6. Replace all sealing rings.

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Steering cylinder - Inspect Inspection 1. Wash all the components with an appropriate solvent and air dry them. 2. Inspect all parts for wear and damage. Small filings and burs can be removed with an extremely fine sandpaper (No.1200). 3. Check whether there is play in the ball joints. Replace them as necessary.

LAIL11TS0139A0A

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Steering cylinder - Travel adjust Steering travel adjustment 1. Adjust the steering travel by means of a bolt, so that the tires and the mudguards do not tough the sides of the tractor and the pistons do not reach the end of run, Fig. 1.

LAIL11TS0146A0A

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Steering cylinder - Disassemble 1. With an appropriate 'C' screwdriver, unscrew and remove the sealing nut. 2. Using a punch, push the steering cylinder bush into the cylinder and remove the lock ring. 3. Extract the connecting rod and bushing set out of the cylinder.

LAIL11TS0147A0A

LAIL11TS0148A0A

4. Remove the nut from the cylinder rod and disassemble to replace the sealing rings. 5. Inspect the cylinder diameter and replace if it is scratched. 6. Assemble the cylinder in the inverse order to that of disassembly, lubricating all the components as they are assembled. Replace all the sealing rings supplied in the service sealing ring kit. NOTE: The seal placed in the center of the bush is replaceable.

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Steering cylinder - Remove 1. Place the tractor on a flat surface and apply the parking brake. 2. Disconnect the flexible tubes, cover the open ends of the tubes and remove the clamps on the tubes. NOTE: The position of the flexible tubes and the orientation of the joints must be the same after reinstallation. 3. Remove the lock ring fixing the steering arm to the articulated pin of the cylinder piston, item (6), Steering cylinder - Overview (41.216) and remove the articulated pin. 4. Remove the mounting screw from the articulated pin fixed on the end of the steering cylinder and remove the articulated pin, item (1), Steering cylinder - Overview (41.216). Remove the cylinder from the vehicle.

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Steering cylinder - Install Installation is done by reversing the removal procedure

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Steering cylinder - Remove 1. Put the tractor on a flat surface and apply the parking brake; 2. Disconnect the flexible tubes, cover the open ends of the tubes and remove the clamps on the tubes. NOTE: The position of the flexible tubes and the orientation of the joints must be the same after reinstallation. 3. Remove the locking ring fixing the steering arm to the articulated pin of the cylinder piston, item (6), Fig. 1 and remove the articulated pin. . 4. Remove the mounting screw from the articulated pin fixed on the end of the steering cylinder and remove the articulated pin, item (1), 1. Remove the cylinder from the vehicle. 5. Installation is done by reversing the removal procedure

40-25-38 SHG

Figure 41: Installation of Steering Cylinder -- Four Wheel Drive. 1. Articulated pin; 2. Articulated pin; 3. D washer; 4. Spacer; 5. Spacer; lock. 6. Ring

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Index Steering - 41 Cylinders - 216 Steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Steering cylinder - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Steering cylinder - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Steering cylinder - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Steering cylinder - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Steering cylinder - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Steering cylinder - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Steering cylinder - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Steering cylinder - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN

SERVICE MANUAL Electrical systems

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55

[55.000] Electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.015] Engine control system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.610] Ground speed control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.030] Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10 [55.404] External lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.11 [55.405] External lighting switches and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.12

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Contents Electrical systems - 55 Electrical system - 000

TECHNICAL DATA Electrical system Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Electrical system Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical system - General specification Electrical equipment specifications Alternator (tractors with platform / without air conditioning) Alternator (tractor with cab / with air conditioning) Regulator Battery Starter Lamp type & size

12 V, 65 A 12 V, 120 A Integrated with the alternator Of the minimum maintenance type - 12 V 750 cca Iskra 3.0 kW Headlights 60 W/ 55 W -- H4 Position lights 5 W -- right hand side 5 W Working Lights 55 W -- H3 Rolling warning 21 W -- P 21 W Brake/Tail Lights 21 W/ 5 W -- P 21 W/ 5 W

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Electrical system - Prepare Recommendations for charging batteries or performing welds on the tractor Protection To avoid damage to the electronic/electric systems, always observe the following: 1. Never make or break any of the charging circuit connections, including the battery connections, when the engine is running. 2. Never short-circuit any load components of the connection to earth. 3. Do not use a slave battery of higher than 12 V nominal voltage. 4. Always observe the correct polarity when installing hew batteries or using a booster battery to help start the engine. Follow the instructions in the Operator's Manual when the tractor is put to work by impulse. Connect positive to positive and negative to negative. 5. Always disconnect the earth cable from the batteries before carrying out arc welding on the tractor or on any implement attached to the tractor. 6. Position the clamp of the connecting cable to earth of the welder as close as possible to the welding area to assure a good connection to earth. 7. Never allow welding cables to lie on, near or across any electrical wiring or electronic component while welding is in progress. 8. Always disconnect the negative cable from the batteries when charging the batteries on the tractor with a battery charger.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

NOTICE: Failure to switch of the two connections of the connecting cable to earth on the battery before proceeding with charging or welding on the tractor or on the headlights connected to the tractor, will result in damage to the electronic or electric systems.

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Service precautions To avoid damage to the alternator recharge installation components the servicing precautions should be observed as follows: DO NOT EVER switch on or switch off any of the recharge circuit connections, including the battery, with the engine running. NEVER connect any of the load circuit component directly to the mass. ALWAYS disconnect the mass cable (negative) of the battery when charging the battery in the tractor, using a battery charger. ALWAYS comply with the correct polarity when installing a battery or when using a booster battery to start the engine. ATTENTION: CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

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LAIL11TS0175A0A

Index Electrical systems - 55 Electrical system - 000 Electrical system - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Electrical system - Prepare . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - 55 Harnesses and connectors - 100

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Contents Electrical systems - 55 Harnesses and connectors - 100

TECHNICAL DATA Wire connectors General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Fuse and relay box General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Wire harnesses Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electrical schematic sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical schematic sheet 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Electrical schematic sheet 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE Wire harnesses Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Wire connectors - General specification Connectors Reference Connector A

No. Cavities 11

Connector B

Connector C Connector D Connector E Connector F

6 6 20 6

Connector G

Connector H Connector I Connector J

10 1 3

Connector K

Connector L

Connector M Connector N

1 2

Connector O

Connector P

Connector Q

CONNECTOR R

Connector S Connector T Connector U

1 1 2

Connector V

Connector X Connector Y Connector W

3 2 4

Connector Z

Connector AB

Interface Main / Engine

Connector: Manufacturer/Reference Connector: manufacturer / Reference AMP-344267-1 (female) PN CNH 82002274 Main / Hood AMP-34426-1 (male) PN CNH 82002272 Main / LH side mudguard To be defined - (Male and female) Main / RH side mudguard To be defined - (Male and female) AMP - 174952-1-070 multilock 20 ways Main / Dashboard Engine / Electric harness - cold start To be defined - (Male and female) Cold start electric harness / Power AMP - 282080-1 ( PN CNH 82992299) play AMP - 1-963214-1 GHC / Electric harness - cold start Injected connector - SL 102.10-B Main / Dual power solenoid Engine / Water in fuel sensor AMP - 881742-1 Main / INT. safety start and INT. Injected connector - SL 102.10 reversing alarm Delphi packard - 12078090 ( PN CNH Engine / Temperature sensor - 87418311) Engine / Cut off solenoid AMP superseal - 282079-2 Engine / Air filter restrictor AMP - 963345-3 Injected connector ( PN CNH Main / Front service lights and rear 82921040) Engine / INT. oil pressure AMP superseal - 282079-2 COBO - 30.16.04093 ( PN CNH Main / Warning switch 5148446) MOLEX 35955-0320 ( PN CNH Main / indicator Switch 87592096) SWF 596989 - ( PN CNH - 9503638) Main / INT 4WD SWF 596989 - ( PN CNH - 9503638) Main / INT. dual power Main / Spy warning switch SWF 913.328 - ( PN CNH 82944053) Main / Spy INT. 4WD / Dual power / SWF 913.328 - ( PN CNH 82944053) Service light Hood / Front lights AMP - 150653-1 AMP - 282080-1 ( PN CNH 82992299) Hood / Front lamps Main / INT. service light COBO - 30.16.04092 Connector - COBO 30.16.04050 ( PN CNH 82918052) Main / INT. brake; INT. safety PTO; cover (protection) - COBO 17.117.103 INT. hand brake ( PN CNH 82918370) COBO - 30.16.0559401 ( PN CNH Main / Starting commutator 51659710) See cavity indications

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Electrical systems - Harnesses and connectors

Fuse and relay box - General specification Fuses and relays The Main Distribution Panel (MDP), or fuse box is under the instrument panel on the left side. Loosen 4 quick latches (1) to remove the metal cover and then have access to the fuse box and relays. There are spaces for 18 fuses in the fuse box, although not all are operational in your tractor. Incorporated into the fuse box (Fig. 2) the relays required for working the high current demand circuits are installed.

LAIL11TS0150A0A

LAIL11TS0151A0A

Some items may not be fitted to your tractor, however, the fuses for these features are installed and can be used as spares. NOTICE: Burnt/different capacity fuses.

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Fuse box layout (IV)

LAIL11TS0002H0A

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Fuses Numero 1 2 3 4 5 6 7 8 9 10 11 12 13

Capacity 5A 5A 5A 15 A 5A 15 A 15 A 10 A 15 A 25 A 15 A 15 A 15 A

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Description Dashboard Brake lamps Dual power and 4wd solenoids High beam Rear working lights Dim-dip lamps Low beam Horn Flasher and flasher lamp relays Light switch Int. horn and reversing alarm GHC Front service lights

Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schema index ELECTRIC SCHEMATIC - SX NEF TRACTORS Color legend 0 1 2 3 4 5 6 7 8 9 10 11

Black Brown Red Orange Yellow Green Blue Violet Gray White Light green Pink

Circuit identification Circuit 1.0 3 850

“1,0 - 3 - 850” Identify the cable gauge IN mm2 Identify the circuit color according to the legend Circuit number Grounding on chassis

Faston female connector W/ insulation

Circuits in accordance with Engineering Specification for identifying circuit color of CNH 82035837 REV. B. Circuits Circuit descriptions Battery feed Ignition feed Light switch feed Fuel level bouy Oil pressure sensor Temperature sensor Indicator and warning switch feed Right flasher Left flasher Earth Accessory feeds Horn relay feed Left brake lamp Right brake lamp

Circuit number 1 10 15 29 31 39 44 49 50 57 71 376 820 830

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Page 1 1, 2, 3 2, 3 2, 5 1, 2 1, 2, 5 2, 3 2, 4 2, 4 1, 2, 3, 4, 5 3 3 4, 5 4, 5

Electrical systems - Harnesses and connectors

INT. feed brake Service light Service light fuse INT. service start Start relay Dashboard feed Horn relay feed INT. air filter restriction Lamp - alternator warning Ignition relay spool feed Fuse feeds Right dim-dip lights Left dim-dip lights Warning switch feeds (battery) Warning switch feeds (ignition) High beam High beam fuse Low headlamp fuse LOW BEAM Panel lighting INT. feed reversing alarm INT. feed - front service light Front service light Warn. cold start GHC - signal to / relay GHC - feed Fuse for cold start relay Cold start relay PI heating plug Reversing alarm feed Starting solenoid feed Horn Tachometer signal Water in fuel sensor Engine cut off solenoid Flasher relay feed (terminal 49) Dual power solenoid Dual power on indicator 4WD solenoid 4WD on indicator

840 997 998 1000 1001 1003 1004 1005 1006 1010 1011 1013 1014 1021 1025 1027 1028 1029 1030 1031 1050 1070 1073 1135 1140 1141 1142 1143 1160 2003 2011 2015 2040 2041 3000 3020 3022 3025 3045

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3, 5 3, 4 2, 3 2, 5 1, 3, 5 2, 3 2, 3 1, 2 1, 2, 5 2, 3 3 3, 4 3, 4 2 2, 3 3, 4 2, 3 2, 3 3, 4 2, 3 3, 5 2, 3 2, 4 1, 2 ,5 5 1, 3, 5 1, 5 5 5 1, 3 3, 4 1, 2 1, 2 1, 2 2, 3 2, 3, 5 2 2, 3, 5 2

Electrical systems - Harnesses and connectors

Wire harnesses - Electrical schematic sheet 01 Cold start system

LAIL11TS0003H0A

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Wire harnesses - Electrical schematic sheet 02 Engine components

LAIL11TS0004H0A

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Wire harnesses - Electrical schematic sheet 03

LAIL11TS0005H0A

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Wire harnesses - Electrical schematic sheet 04

LAIL11TS0006H0A

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Wire harnesses - Electrical schematic sheet 05

LAIL11TS0007H0A

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Wire harnesses - Electrical schematic sheet 06

LAIL11TS0008H0A

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Wire harnesses - Overhaul Temporary repair of the cable The following method for repairing the cable is only a temporary solution. The cable must be replaced as quickly as possible. Replacement of the temporarily repaired wires by new ones is of the utmost importance if the tractor is used for spraying work, because the chemical products could enter the repaired areas and damage the electrical components. NOTE: When repairing the cables it is of the utmost importance that only SOLDER WITH A RESIN CORE is used. Use of other types of solder may result in further cable damage. LAIL11TS0161A0A

LAIL11TS0162A0A

LAIL11TS0163A0A

To make temporary repairs, proceed in the manner indicated as follows:1. Locate damaged portion of cable then cut away outer protective cover on both sides of the damaged area. Fig. 1. 2. Peel back the cable from both ends of the damaged area and carefully cut away the inner cable cover in the damaged area and strip about 13 mm (0.5 ft) of insulation from the wires. Do not cut any wire strands. 3. With the appropriate solvent, clean around 50 mm (2 ft) from each extremity of the cover. Clean the grey cable cover and the individual leads. 4. Twist two bare leads together for each damaged lead, taking care to match wire colors, then solder the leads using resin cored solder. Tape each repaired lead with vinyl insulation tape, Fig. 2. 5. Wind a layer of vinyl insulation tape up to the grey cable cover at each end of the repaired section. Make a paper trough, Fig. 3, then apply silicon rubber compound (non hardening sealant) over the repaired section up to the cover ends. Use sufficient sealant to fill the ends of the area to be cut.

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6. Allow the mixture to seat and then cover the area with insulating tape, covering each of the repaired ends very well. An overlap of at least 50 mm (2 ft) of tape on each of the ends is necessary, Fig. 4. 7. Make sure that the repair has been well down and hold the repaired cable to prevent the damage from being repeated. NOTE: This is only a temporary repair. Ensure that the cable is replaced as quickly as possible to prevent the entry of water or chemical products.

LAIL11TS0164A0A

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Index Electrical systems - 55 Harnesses and connectors - 100 Fuse and relay box - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Wire connectors - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Wire harnesses - Electrical schema index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Wire harnesses - Electrical schematic sheet 01 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Wire harnesses - Electrical schematic sheet 02 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Wire harnesses - Electrical schematic sheet 03 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Wire harnesses - Electrical schematic sheet 04 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wire harnesses - Electrical schematic sheet 05 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Wire harnesses - Electrical schematic sheet 06 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Wire harnesses - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Electrical systems - 55 Engine control system - 015

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Engine control system - 015

FUNCTIONAL DATA Engine control system Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine control system

Engine control system - Component localisation

BRAG11TR0151LUE

1. 2. 3. 4. 5. 6. 7. 8. 9.

Coolant temperature sensor. Starter motor. KSB water temperature sensor. Electromagnets fitted on the supply pump: (A) on the body of the hydraulic head (B) on the KSB. Fuel heater (C) in water sensor (D) (if available). Oil pressure switch. Speed sensor. Cold start resistance (if available). Alternator.

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Index Electrical systems - 55 Engine control system - 015 Engine control system - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine starting system - 201

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Engine starter Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Engine starting system Replace Starter Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Engine starter Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine starter - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Engine starting inhibitor switch Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Electrical systems - Engine starting system

Engine starter - Torque Torque values Nm Starter motor to block fixing bolts Solenoid cable nuts Starter motor cover nuts Solenoid fixing bolts

34 N路m 7 N路m 10 N路m 5 N路m

Kgf/m 3.4 Kgf/m 0.7 Kgf/m 1.0 Kgf/m 0.5 Kgf/m

Engine starter - General specification Specifications

Maximum intensity without load at 12 V and 8000 RPM Minimum length of brushes Minimum diameter of manifold Maximum clearance of armature

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Type of starter motor Iskra - 3.0 kW 80 A 7.00 mm 42.5 mm 0.4 mm

Electrical systems - Engine starting system

Engine starting system - Dynamic description Operation The starter motor system installed in the mechanical transmission has various basic components, namely: a keyactivated starter motor switch, a safety cut-out installed in the transmission, heavy duty cables, a starter motor and solenoid and a starter motor relay. The starter motor 3.0 kW is a four-pole, four-brush type motor with integrated solenoid assembly and positively engaged transmission. The integrated solenoid incorporates 2 armatures connected in parallel. One armature has a low resistance "pulling" coil and is earthed by the engine. The other armature has a high resistance "maintain" coil and is earthed by the solenoid body. When the starter motor switch is connected with the transmission in neutral, the solenoid coils are activated and its piston is attracted magnetically to the solenoid core. This movement is transmitted by an articulated mechanism and forces the drive pinion onto the flywheel rack. When the drive pinion touches the flywheel rack, the solenoid piston acts to close a group of contacts, which in turn supply energy directly from the battery to the four field coils that deliver all the power to the starter motor. At this point, one end of the “pulling” coil connects to the battery positive side through the starter switch, while the other end is connected to the positive through the solenoid contacts. The “pulling” coil is thereby disconnected from the circuit and does not receive any power, while the holding coil maintains the solenoid piston engaged. The starter motor incorporates a set of single contacts and a two-part solenoid piston that close the contacts completely even if the sprocket and the pinion teeth are misaligned. When this happens the engagement spring is compressed which forces the pinion to engage completely so the starter motor starts to turn. When the starter motor switch is released, power to the solenoid and to the starter motor is cut. The solenoid return spring acts with an articulated mechanism disengaging the pinion gears and reopening the solenoid contacts. The drive pinion assembly incorporates a roller clutch. This clutch prevents the armature turning excessively if the drive pinion remains engaged to the rack after the engine starts. The starter motor switch (1) installed in 8 x 2 and 16 x 4 transmissions means that the engine can only be started with the range selector lever is in neutral.

LAIL11TS0011A0A

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Electrical systems - Engine starting system

Engine starter - Exploded view

LAIL11TS0008G0A

Starter motor -- view of disassembled parts in their relative positions 1. Fixing bolt 2. Cover 3. Set of collars and rings, command drive 4. Brush cover 5. Brush 6. Brush 7. Coil covering 8. Armature 9. Central support plate 10. Bushing

11. 12. 13. 14. 15. 16. 17. 18. 19.

Covering Solenoid Solenoid nuts and bolts Lever Brush spring Brush support Washer Nut Drive pinion assembly

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Electrical systems - Engine starting system

Engine starting system - Replace Starter Key Switch 1. Disconnect the tractor's negative battery cable. 2. Remove the steering rod covers. 3. Disconnect the connector (2), remove the nut (1) fastening the switch to the cover. 4. To reinstall, carry out the removal procedure in reverse.

LAIL11TS0411A0A

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Electrical systems - Engine starting system

Engine starter - Install Starter motor removal 1. Disconnect from the battery the connecting wire to the mass (negative). 2. Remove the solenoid protective cover and disconnect the positive wires to the solenoid and the feed wire from the solenoid to the coil. 3. Remove the three starter motor fixing bolts and remove the starter motor. 4. Assemble by following the disassembly procedures in the inverted order.

LAIL11TS0169A0A

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Electrical systems - Engine starting system

Engine starter - Remove Starter motor removal 1. Disconnect the battery ground cable (negative). 2. Remove the protective cover of the solenoid assembly (1). Disconnect the positive cables from the solenoid and disconnect the power supply wires from the solenoid coil.

LAIL11TM0723A0A

LAIL11TM0995A0A

3. Remove the three mounting bolts (1) from the starter motor (2). Remove the starter motor.

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Electrical systems - Engine starting system

Engine starter - Assemble Assembly 1. Assembly is done in the inverse order of disassembly. Before assembly, check the armature longitudinal clearance and test operation without load on the starter motor.

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Electrical systems - Engine starting system

Engine starter - Disassemble Disassembly See Engine starter - Exploded view (55.201) 1. Support the starter motor on a vise. 2. Disconnect the thick plaited cable from the field coil covering to the solenoid. 3. Remove the three bolts out of the covering and disassemble the solenoid. The piston remains on the command engage lever. 4. Split the solenoid piston out of the command lever by grabbing the piston and lift its front end to loosen it out of the command lever. 5. Remove the two nuts and bolts that fasten the brush cover and plate on the covering. Remove clamp 'C' and the armature shaft clearance bushings and remove the covering leaving the brushed on the manifold. Remove the soft metal washer from the armature, manifold side. 6. At this disassembly stage, inspect the brushes and manifold. Check if the brushes are stuck and if necessary clean the brushes and their supports with a cloth dampened with gasoline. Check the brushes for wear and if they are worn beyond the minimum specified length of 7.00 mm the starter motor needs replacement. NOTE: The brushes cannot be obtained separately as spare parts. They are welded with points in place and must not be replaced throughout the starter motor working duration. 7. Remove the carcass by splitting it from the armature and support on the drive side. 8. Remove the engage lever articulation bushing out of the covering on the drive side. 9. Remove the drive assembly and the retaining ring from the inside plate out of the armature shaft extracting the drive collar and fixing just to the right out of the retaining ring with a tube of adequate diameter and then remove the retaining ring out of its groove. 10. Extract the armature and drive assembly.

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Electrical systems - Engine starting system

Engine starter - Overhaul Armature 1. Clean the manifold surface and remove the burnt points. If necessary, remove. 2. If the manifold needs to be reconditioned, check that the diameter is not below the specified minimum of 42.5 mm. 3. After servicing, polish the manifold with a fine emery paper then clean with a cloth smeared with Vaseline. NOTE: Do not cut the metal manifold to cut isolating grooves. 4. The armature isolation can be checked by connecting an ohmmeter between the manifold segments and the armature shaft. The reading must be infinite, that is, no continuity. 5. To check for a short circuit in the armature, suitable equipment is needed to test it, or alternatively test by replacing it. 6. If there are signs that the circumference of the armature is in contact with the pole earths, the armature bearings are probably excessively worn. 7. First check that the pole earths are well tightened and that the armature turns freely in a clamp. If necessary, replace the armature bearings.

Bearings 8. Examine the brush cover bearings and the cover on the side of the drive for wear. Install the armature shaft and check the gap for replacing the bearings if the gap seems to be excessive. Check the pole earths for signs of wear with the armature that may be the result of worn brushes.

Drive pinion 9. Check compressor clutch operation. The pinions must only turn clockwise. If the pinion is stuck, turns in both directions, or if the teeth are damaged, install a new drive unit. If the drive pinion teeth are clearly damaged, it is also worth checking the teeth of the engine flywheel rack.

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LAIL11TS0171A0A

Electrical systems - Engine starting system

Engine starter - Electrical test Rehearsal of the starter system on the tractor For easier and quicker diagnosis and to obtain a majority of conclusive rehearsals it is recommended to use a device to check batteries/starter motors (quick discharge verifier) that incorporates a 0 - 20 v volt meter and a 0 - 500 A amp meter to diagnose trouble in the starter system. When using the rehearsal equipment, always follow the manufacturer recommendations regarding the rehearsal procedures. When no rehearsal equipment is available, use a 0 - 20 V volt meter and a 0 - 500 A amp meter and follow the procedures below to determine correct operation of the starter motor without disassembling it from the engine. Before rehearsals: • Check if the battery is fully charged. • Check the set of wires in the starter system circuit for split, frayed wires, or loose connections. • Make sure the engine is not locked.

Current demand from the starter motor circuit 1. Disconnect from the battery the connecting wire to the mass (3). 2. Disconnect the battery wire on the starter solenoid. Connect the amp meter positive wire (1) to the battery positive terminal and the negative to the solenoid input terminal. 3. Reconnect to the battery the connecting wire to the mass (negative). 4. Connect the volt meter positive wire (2) to the battery positive terminal and the negative to the battery negative terminal. 5. Disconnect the solenoid wire from the injection pump. 6. Turn the motor and at the same time observe the readings on the volt meter and amp meter. The volt meter voltage must remain stable at 12 V and the amp meter intensity at 250 - 300 A. • If the current demand is within specification, the starter motor (4) is working correctly. If there is a voltage drop during the rehearsal, see the procedures indicated under the title [Invalid Reference]. • If the current demand is higher than the specified, check the circuit as specified below. If the starter system circuit rehearsals prove satisfactory, then the starter motor is damaged and must be disassembled to determine the causes. • If the current demand is lower than the specified, the starter motor is damaged and must be disassembled to determine the causes. Starter system circuit resistance (Voltage drop)

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LAIL11TS0165A0A

Electrical systems - Engine starting system

If there is an excessive current demand the circuit must be checked noting the voltage drops on each circuit component. NOTICE: Disconnect the fuel injection pump cut off solenoid wire.

Battery positive wire: 1. Connect the volt meter positive wire to the battery positive terminal. 2. Connect the volt meter negative wire to the starter motor solenoid battery terminal. 3. Turn the engine and at the same time observe the voltage reading on the volt meter. If it is higher than 0.2 V, check and tighten the wire connections. Check the voltage again, if it is still excessive, place new cables.

LAIL11TS0166A0A

LAIL11TS0167A0A

LAIL11TS0168A0A

Starter motor connection to the mass: 1. Connect the volt meter positive wire to the starter motor frame. 2. Connect the volt meter negative wire to the engine block. 3. Turn the engine and at the same time observe the voltage reading on the volt meter. If it is higher than 0.2 V, check the connections to the mass between the starter motor flange and the plate behind the motor.

Connection wire from the mass to the battery: 1. Connect the volt meter positive wire to the engine block. 2. Connect the volt meter negative wire to the battery negative terminal. 3. Turn the engine and at the same time observe the voltage reading on the volt meter. If it is higher than 0.2 V, check and tighten the wire connections to the mass. Check the voltage again, if it is still excessive, assemble new cables.

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Electrical systems - Engine starting system

Rehearsal without starter motor load: NOTE: To carry out this rehearsal a fully charged battery is required as well as a battery checking device (quick discharge check) with carbon disk rheostat (variable charge resistance). 1. Fasten the starter motor on a vise. 2. Connect the battery negative cable (4) to the starter motor mounting flange. 3. Make a bridge connection with a short wire (6) between the battery solenoid terminal and the solenoid switch terminal. 4. Connect the volt meter positive wire (3) to the battery positive terminal, the volt meter negative wire to the battery negative terminal, the amp meter positive wire (1) to the battery positive terminal and the amp meter negative wire to the starter motor terminal or the terminal on the solenoid that will connect to the battery.

LAIL11TS0170A0A

LAIL11TS0172A0A

5. Hold a manual tachometer (5) on the end of the armature shaft. Activate the starter motor adjusting the carbon stack rheostat (2) to deliver 1.7 V. When the armature speed is between 7500 - 8500 RPM, the maximum current output must not be over 160 A. 6. If the starter motor does not operate according to specifications, check for leaks to the inductor coils, if the armature is rubbing or if its shaft is twisted.

Inductor coils 1. To test isolation of the inductor coils, connect and ohm meter between each brush and any point on the covering that is clean and free of paint. There should be no continuity. 2. To test isolation of the inductor spools, connect an ohm meter between each brush and the main feeding terminal (thick plaited wire). There should be a reading of 1 Mega ohm. 3. If there is damage to the inductor spools the complete inductor coils and the covering assembly must be replaced.

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Electrical systems - Engine starting system

Engine starter - End play Checking the longitudinal armature clearance: 1. Fasten the starter motor to a vise and assemble a calibration gauge on the covering flange, drive side. Place the gauge point on the end of the armature shaft. 2. Move the armature fully forward and place the gauge to zero. Move the shaft completely backward and record the calibration gauge reading. 3. The reading must not exceed 0.4 mm. If the reading exceeds this value, inspect the armature and the brush cover for wear. Replace the worn components and check the longitudinal clearance again.

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Electrical systems - Engine starting system

Engine starter - Electrical test Starter motor with no load test: NOTE: To run this test, you will need a well-charged battery and a battery tester (to check rapid discharge) with carbon disc rheostat (variable load resistance). 1. Put the starter motor in a vice. 2. Connect the battery's negative cable (4) to the fixing flange on the starter motor. 3. Make a bridge with a short wire (6) between the terminal on the battery solenoid and the terminal on the solenoid breaker. 4. Connect the positive wire of the voltmeter (3) to the battery's positive terminal and its negative wire to the battery's negative terminal, the positive wire (1) of the ammeter to the battery's positive terminal and its negative wire to the starter motor terminal or to the terminal on the solenoid that will connect to the battery. 5. Fix a manual tachometer (5) to the point of the armature shaft. Activate the starter motor, adjusting the rheostat on the carbon batteries (2) to give 11,7 V . When the armature's rotation speed is between 7500 - 8500 RPM , the maximum current demand must not be higher than 160 A . 6. If the starter motor does not work as specified, check whether there are holes in the induction coils, the armature is torn or the shaft is twisted.

LAIL11TL0162A0A

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Electrical systems - Engine starting system

Engine starter - Electrical test Induction coils 1. To test the insulation of the induction coils, connect an ohmmeter between each of the brushes and any part of the case that is clean and paint-free. There should no continuity. 2. To test the insulation of the induction spools, connect an ohmmeter between each of the brushes and the main power supply terminal (large twisted wire). There should be a reading of 1 Mega ohm. 3. If there is a fault in the induction spools, the entire induction coils and cover assembly will have to be replaced.

LAIL11TS0172A0A

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Electrical systems - Engine starting system

Engine starting inhibitor switch - Remove Dismounting 1. Remove the change cover as described previously. 2. Unscrew the start motor inhibitor switch from the housing. 3. Check if the start motor inhibitor switch is worn or damaged. Replace if necessary.

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LAIL11TS0011A0A

LAIL11TS0012A0A

Electrical systems - Engine starting system

Engine starting inhibitor switch - Install Reassembly and installation 1. To reassemble and install the starter motor inhibiter switch, follow the reverse procedure from disassembly. 2. Test switch operation with a multimeter. NOTE: Do not move the actuator housing more than 6.0 mm (0.24 in) from the actuator guide centre line or the guide may come out of the rod.

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LAIL11TS0011A0A

LAIL11TS0012A0A

Index Electrical systems - 55 Engine starting system - 201 Engine starter - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Engine starter - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Engine starter - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Engine starter - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine starter - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Engine starter - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Engine starter - End play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Engine starter - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Engine starter - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starter - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Engine starter - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Engine starter - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Engine starting inhibitor switch - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Engine starting inhibitor switch - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Engine starting system - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine starting system - Replace Starter Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Electrical systems - 55 Alternator - 301

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Alternator Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Regulator - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Electrical systems - Alternator

Alternator - General specification Specifications

Polarity Rated voltage Maximum R.P.M. Maximum debit Regulator controlled voltage Rotor field spool resistance Stator field spool resistance Length of new brushes Minimum brush length Brush spring pressure

Type of Alternator: Iskra - 65 A P.N. 87576058 Negative to Mass 12 V 15000 RPM 55 A 13.6 - 14.4 V 2.9 Ω 0.2 Ω 20.0 mm 5.0 mm 1.3 - 2.7 N

Torque values Nm 5.5 N·m 70.0 N·m 4.0 N·m 2.7 N·m 2.7 N·m

Bolts that cross the alternator Pulley retaining nut Redresser fixing bolts Voltage regulator and brush box bolts Terminal nuts

Alternator - General specification Polarity Nominal voltage Maximum RPM Maximum debit Controlled regulator voltage Rotor field winding resistance Stator field winding resistance Length of new brushes Minimum brush length Brush spring pressure

Alternator type: Iskra – 65 A P.N. 87576058 Negative with earth 12 V 15000 RPM 65 A 13.6 - 14.4 V 2.9 Ω 0.2 Ω 20.0 mm 5.0 mm 1.3 - 2.7 N

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Kgf/m 0.5 Kgf/m 7.0 Kgf/m 0.4 Kgf/m 0.3 Kgf/m 0.3 Kgf/m

Electrical systems - Alternator

Alternator - Exploded view 65 A alternator components

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Redresser assembly

Pulley retaining nut

Pulley

Cooling fan

Front part housing

Stator

Rotor

Regulator and brush box assembly

Rear part housing

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Electrical systems - Alternator

Alternator - Detailed view 65 A Alternator 1. Connection to earth (Mass) 2. Connection of engine speed sensor (Terminal W) 3. Warning light (Terminal D+) 4. Out connection (Terminal B+) 5. Terminal protection sleeve

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Electrical systems - Alternator

Alternator - Dynamic description Alternator operation With reference to Fig. (55.301).

Alternator - Detailed view

When the starter switch/ignition key is switched on, there is a low value current that leaves the batter and passes through the rotor field spool. The circuit is established through the warning light that indicates the charge of alternator terminal 'D+', the rotor field spool, the alternator and mass voltage regulator. In this phase the warning light turns on and the rotor is partially magnetized. When the engine starts and the partially magnetized rotor starts spinning between the stator spools, a three phase current is generated. A constant amount of the generated current is converted into continuous current by the three field diodes incorporated in the redresser set. This continuous current returns to complement the current that passes through the rotor field spool. The result of this action is a continually growing magnetic induction of the rotor, associated with a rapid increase in the supply of current and voltage. During the increase of the voltage supplied (available in terminal 'D+') the warning lights dims down and when the tension on terminal 'D+' equals the tension on the battery side, the warning light goes out. The voltage continues to increase until the preset voltage level is reached. In case the transmission belt breaks, no voltage is generated in the alternator and the light will stay on to indicate the fault.

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Electrical systems - Alternator

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Alternator charging circuit A For the starter motor B For the starter motor relay C Rotation sensor terminal for the group of instruments (panel) 1. Starter motor solenoid 2. Battery 3. Rotor field spool

4. Voltage regulator 5. Alternator structure 6. Stator output spool 7. Redresser Set 8. Charge indicator lamp 9. Ignition switch/key ignition.

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Electrical systems - Alternator

Alternator - Dynamic description â&#x20AC;˘ The alternator used is a 65 A model with an exterior cooling fan. The alternator is fitted on the front section of the engine and is operated by the crankshaft pulley using a V belt. The alternator has an integrated electronic tension regulator.

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Electrical systems - Alternator

Alternator - Overhaul Inspection and repair 1. Inspect the rotor poles and stator for signs of friction. The appearance of friction zones indicates the possibility of there being worn bearings, misaligned housings or a bent rotor assembly shaft. NOTE: The bearing at the front of the 55 A alternator cannot be replaced separately. A new redresser and housing assembly or a stator assembly is needed to replace the worn bearings. 2. Inspect the 65 A alternator bearings (1), located on support (2) of the rear part (slide ring), for wear and other damage. 3. If the bearing needs replacement, support the housing (rear bracket) and with an adequate sized mandrill carefully extract the bearing, Fig. 1.

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4. Clean and check all the components. 5. Press the new bearing (2) to the housing (1). The bearing must stand out 0.50 - 0.70 mm from the internal face of the bearing case, as shown in item (3), Fig. 2.

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Electrical systems - Alternator

Alternator - Remove Servicing the alternator and testing the components Remove the Alternator With reference to Fig. 1. 1. Disconnect the negative battery cable. 2. Disconnect the four cables from the rear of the alternator. 3. Remove the alternator drive belt as follows: Put a long cable or lever between the stretcher fixation base and tensioner bearing rod. Next, pull the stretcher upwards, Alternator - Check (55.301) . Remove the fan belt from the pulley and allow the stretcher to return to its free position after the belt has been removed. 4. Dismount the alternator arm (2) and the bottom bolts and remove the alternator (1) from it support (3) on the engine.

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Electrical systems - Alternator

Alternator - Install Installation 1. The alternator is installed in reverse order from disassembly. When installing, observe the following: Ensure that the battery ground (negative) cable is disconnected when installing the alternator. Install and check the alternator drive belt.

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Electrical systems - Alternator

Alternator - Assemble Assembly 1. Alternator installation follows the dismounting procedures, but in reverse order. When installing the 65 A alternators, note the following: To prevent misalignment of the extremity brackets, install the stator assembly on the drive part support, and afterwards install the support on the slide ring side on the stator blades.

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Electrical systems - Alternator

Alternator - Disassemble Disassembly -- 65 A Alternator Refer to Figure Alternator - Exploded view (55.301) 1. Remove the four nuts that fix the terminal block to the alternator. 2. Remove the nut from the temperature sensor terminal block. 3. Remove the three fixing bolts and separate the regulator/brush box assembly. 4. Unbolt and remove the three remaining nuts from the bolts that cross the alternator. With a mallet, tap the threaded part of said bolts to free the salience on the side of the hex head bolt. 5. Mark the support of the front part of the alternator to guarantee correct alignment during assembly. 6. Gently tap the rear support surface of the front part of the alternator to separate it and the rotor assembly out of the rear support surface of the stator and seam set. 7. Remove the nuts, rings and insulators of the threaded terminals on the bracket at the rear part of the alternator, and the two seam fixation bolts. Remove the stator and the seam from the rear clamp. 8. Remove the solder from the stator wires on the seam terminals, using a pair of pliers with a heat dissipater to avoid overheating the diodes. 9. Remove the nut, ring, fan and spacer of the rotor shaft. 10. Push the rotor shaft to free the bearing and the support of the front part.

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Electrical systems - Alternator

Alternator - Check Preliminary checks Before the electrical test, completely inspect the electrical charge and systems. Check all cables and connections for continuity and firmness.

1. Checking the battery Using a densitometer, check the individual elements of the battery. The battery should be at least 70 % charged and in good condition.

2. Checking the drive chain Inspect the alternator activating belt and the pulley to ensure they are both clean, free from oil and lubricant, and in good condition. The alternator activating belt is stretched automatically by a tensioning spring installed in the front of the engine, as shown in detail (2). If the tensioning spring is fatigued, the assembly, which is bolted to the engine, must be replaced - details (1).

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3. Checking the warning light Turn the ignition key/starter motor switch and check that the warning light (1) comes on at full strength. If the warning light does not come on at full strength, check the bulb. If the bulb is not the cause of the anomaly, test the alternator connections as described in "initial tests" in this section. If the warning light is on, start the engine and accelerate to above idling speed. The light should go out. If the light does not go out, switch the engine off and remove the D+ wire from the terminal. If the light does goes out, it indicates a defective component in the alternator. Perform the alternator components tests as indicated in this section. If the warning light stays on, check if there is a short circuit to earth between the end of the 'D +' cable and the warning light.

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Electrical systems - Alternator

Alternator - Electrical test Initial tests The initial tests can be performed without removing any tractor recharge circuit components and allow the following items to be tested: Alternator wire connections Controlled voltage and alternator charging current Alternator recharge circuit voltage drops Maximum alternator debit value Required test equipment: Voltmeter ( 0 - 30 V of the moving coil type) Milivoltmeter ( 0 - 1 V) Amp meter ( 0 - 110 A volts of the moving coil type) Variable load potentiometer of 1.5 ÎŠ, 110 A NOTE: The majority of test appliances sold incorporate the possibility of performing various tests. Use this equipment according to manufacturer instructions.

1. Testing the alternator wire connections Refer to Fig. 1. 1. Disconnect the battery. 2. Disconnect the alternator terminals B+(2) and D+(3). 3. Reconnect the battery and turn the starter switch to the on position, but without running the engine. Connect the voltmeter (4) between each terminal and the earth (ground), (1). There should be voltage on the battery. If there is no voltage on the battery, there is a continuity failure in the external circuit cables which must be located and repaired. See the circuit diagram, Fig. Electrical system - Prepare (55.000). 4. Connect terminal D+, the warning light wire (brown/ yellow) to earth (ground). The warning light must light up. 5. Disconnect the battery and reconnect the disconnected alternator cable connections to the alternator. NOTE: If the warning light does not go on when the cable is reconnected to the alternator, it means there is a fault in the alternator regulator or the rotor circuits. Check if terminal D+ is clean and then perform the alternator component testing as detailed in this section.

2. Controlled voltage and charging current tests Refer to Fig. 2.

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Electrical systems - Alternator

1. Check whether the tractor components are turned off and whether the ignition key is in the 'off' position. 2. Disconnect the negative battery terminal and the B+ terminal of the alternator (4). 3. Connect the amp meter (1) between the removed cable (3) and alternator terminal. 4. Connect the voltmeter (2) between each terminal and the earth (ground). 5. Reconnect the battery. Run the engine and hold it at 2000 RPM and take the amp meter and volt meter readouts. LAIL11TS0177A0A

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The voltmeter should indicate a value above that of the battery voltage, and when the amp meter readout is below 10 A, the voltmeter readout should stabilise between 13.6 V and 14.4 V If the voltmeter readout exceeds 14.4 V, the alternator regulator must be replaced, as indicated in this section. If the voltmeter readout is below 13.6 V volts this indicates that there is a damaged alternator component or a fault due to high resistance on the recharge system external connections. If the amp meter indicates 0 A, this means that there is a defective alternator component. Shut off the engine and perform the 'Testing the alternator components' as indicated in this chapter.

3. Drop in voltage and charging circuit tests (a) Drop in voltage on the insulated side tests Refer to Fig. 3. Check whether the starter motor is in the "off" position. 1. Disconnect the negative battery cable and disconnect alternator terminal B+ (1). 2. Connect a millivolt meter (4) between the battery positive terminal and cable B+ (5). (Connect cable to the positive side). 3. Solidly connect an amp meter (2) between alternator terminal B+ and cable B+ (connect the cable to the negative side).

4. Reconnect the battery negative cable and connect a potentiometer (3) with the cursor on the minimum current passage (maximum resistance) between the battery terminals. 5. Start the engine and increase engine revolutions to 2000 RPM. 6. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A or 120 A, depending on the model being tested.

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Electrical systems - Alternator

7. Note down the millivolt meter reading, it should not be above 400 mV. If the reading is higher than 400 mV, this indicates a high resistance problem in the external circuit. If the expected alternator debit cannot be reached and the millivolt meter readout is under 400 mV, it is because there is a defective alternator component. Perform the alternator components tests as indicated in this section. 8. Shutdown the engine.

(b) Drop in voltage on the earth side tests Refer to Fig. 4. 9. Check whether the starter motor is in the "off" position. 10. The circuit is the same as the one used on the previous test, except that the millivolt meter (4) is now connected between the battery negative terminal and the alternator housing (negative housing side). NOTE: Check whether the potentiometer (3) is regulated for the passage of minimum current (maximum resistance). 11. Start the engine and increase engine revolutions to 2000 RPM. 12. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A or 120 A, depending on the model being tested.

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12. Note down the voltmeter reading, it should not be above 200 mV. If the reading is higher than 200 mV, this indicates a high resistance problem in the external circuit. If the expected alternator debit cannot be reached and the millivolt meter readout is under 200 mV, it is because there is a defective alternator component. Perform the alternator components tests as indicated in this section. 14. Shutdown the engine.

4. Alternator output maximum performance test Refer to Fig. 5. 1. Check whether the starter motor is in the "off" position. 2. Disconnect the negative battery cable and disconnect alternator terminal B+ (5).

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Electrical systems - Alternator

3. Solidly connect an amp meter (2) between alternator terminal B+ (1) and cable B+ (connect the cable to the negative side). 4. Connect a voltmeter (4) between alternator terminal B+ and the earth (ground). 5. Reconnect the battery, start the engine and increase speed to 2000 RPM. 6. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 65 A or 120 A, depending on the model being tested. 7. Note down the voltmeter reading, it should be lower than 13.6 V. If readout is under 13.6 V, this means that there is a defective alternator component. Perform the alternator components tests as indicated in this section.

Testing the alternator components Testing of components should only be performed if the INITIAL TESTS indicate an alternator component fault and allow the checking of the following items: Regulator Rotor continuity of the rotor field spindle Rotor brushes, springs and slide rings NOTE: Testing of the components described above can be performed with the alternator installed in the tractor. Testing other alternator components requires disassembling the alternator from the tractor. See the 'Servicing' section in this Chapter. NOTICE: Before disassembling the alternator cables check whether the ignition key is in the 'off' position and whether the negative battery cable is disconnected. Necessary testing equipment: 12 V BATTERY Multimeter 2.2 W Test light

Insulating the 120 A alternator rectifier 8. Check the insulation between the rectifier and its box. Use an ohm meter (2) to connect the test terminals between the alternator carcass (3) and the positive diode board.

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Electrical systems - Alternator

9. An infinite resistance reading should appear which indicates an open circuit, therefore. If any resistance, that is, a short circuit is indicated, the redresser and its frame assembly must be replaced.

1. Testing the rotor field circuit and voltage regulator Refer to Fig. 7. 1. Disconnect all the cables from the alternator. 2. Connect a battery 12 V with a test light 2.2 W (2) in series between D+ (1) and the alternator housing (connect to the negative side of the housing).

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3. The test light should come on. If the test light does not come on, this means there is a defect in the rotor circuit. Check the brushes, the slide rings and the rotor field spindle continuity. If the test shows that these parts are in good condition, the problem may be in the voltage regulator.

2. Testing the continuity of the rotor field spindle Refer to Fig. 8 . 1. Dismount the brush assembly and regulator assembly, as described in this chapter. 2. Connect an ohmmeter (3) between the two slide rings (2). The resistance reading should be of 2.6 ÎŠ at 20 Â°C.

If the resistance is not within specifications, replace the rotor (1) as indicated in the next section on servicing.

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Electrical systems - Alternator

3. Rotor brushes, springs and slide rings 1. Dismount the brush assembly and regulator assembly, as described in this chapter. 2. Make sure the brushes and the slide rings are clean and check if the brushes move freely in the brush box structure. 3. Check the brush spring pressure with a push type spring gauge and note down the spring pressure when the tip of the brush is in contact with the box. If pressure is lower than specified, install a new regulator and a brush box.

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If the visible length of the brushes (1) in the free position is under 5.0 mm, the probable cause will be an interruption in the field circuit, and therefore the regulator and the brush group assembly must be replaced, Fig. 9. NOTE: The brushes are an integral part of the regulator and the brush box assembly and cannot be replaced individually.

Stator assembly - 65 alternator spindle continuity Refer to Fig. 10. 1. Connect the ohm meter test terminals (3) between the pairs of wires A, B and C (2). There must be a small resistance of 0.1 ÎŠ, between each pair of wires. If it records a higher resistance than this, it will indicate that there are broken wires inside the spindle, that is to say, there is an open circuit. A lower reading, for example, 0.0 ÎŠ, indicates a short circuit in the spindle. If the test is not satisfactory, a new stator (1) and housing assembly may be required.

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Stator test -- 120 A alternator insulation 2. Check the insulation on each spool pair, between them and then between each spool and the alternator box. There should be no continuity between the three pairs of spools between them and between the spools and the box. If an ohmmeter reading (2) is found not to indicate an open circuit, the stator (1) and housing assembly will need to be replaced.

Stator test - 65 A. Alternator isolation Refer to Fig. 12.

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Electrical systems - Alternator

1. Check the insulation of each spindle and alternator box. There should be continuity between the spindle and box. If any ohmmeter readout (2) is found not to be an open circuit, it will be necessary to replace the stator assembly (1).

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Testing the stator -- 120 A alternator spool continuity 2. Connect the ohmmeter test terminals (2) between the A, B and C pairs of wires. There should be a small amount of resistance of 0.1 ÎŠ between each pair of wires. If it records a higher resistance than this, it will indicate that there are broken wires inside the spool, that is to say, there is an open circuit. A lower readout, for example 0 ÎŠ, would indicate that there is a short circuit within the spool. If any of these three wire pairs fails the test, a new stator (1) and carcass assembly is required.

Testing the Rotor Before performing tests on the rotor, the slide rings must be inspected as follows: 1. 1. See if the slide rings are clean and soft. If needed, the slide rings can be cleaned with a cloth dampened with gasoline. If the slide rings are burnt and need repairing, use a very fine sandpaper (do not use an emery cloth) and rub until they are clean. NOTE: Check whether the sandpaper to be used during the repair is fine enough to produce a highly polished surface on the slide ring, otherwise, excessive brush wear will occur. 2. If the slide rings are excessively worn out a new rotor should be installed.

Continuity of the rotor field spindle Refer to Fig. 14.

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Electrical systems - Alternator

1. Connect an ohmmeter (3) between the two slide rings (2). The resistance should be between 2.6 ÎŠ and 20 Â°C. If the resistance does not match the specification replace the rotor (1).

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Insulation of the rotor field spindle Refer to Fig. 15. 1. With an ohm meter (3), test between each slide ring (2) and the rotor terminals (1). In each case, a read out of infinite value must be indicated. If the readout is a resistance value, the rotor assembly must be replaced.

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Electrical systems - Alternator

Alternator Regulator - Electrical test Redresser Assembly - 65A Alternator Positive / Negative Diode Tests With reference to Fig. 1. Test every one of the six diodes separately, as follows: 1. Connect a multimeter (2) in series with one of the diodes. Apply one of the test terminals to the connecting pin (1) of the diode and the other terminal to the plate where the diode is installed. 2. See what the resistance readout is on the multimeter. Invert the test wire connections. 3. The multimeter should indicate an open circuit (infinite resistance), only in one of the test halves. If any of the diodes fail this test, it is necessary to replace the complete redresser.

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Redresser Assembly - Field Diodes, 65A Alternator With reference to Fig. 2. Test every one of the six field diodes separately, as follows: 1. Connect a multimeter (2) in series with the field diode module. Apply the negative terminal of the test appliance to the terminal D+ (1) connection and the other terminal to each one of the field diode connections in turn (3). 2. See what the resistance readout is on the multimeter. Invert the test wire connections. 3. The multimeter should indicate an open circuit (infinite resistance), during only half of the test. If any of the diodes fail this test, it is necessary to replace the complete redresser.

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Index Electrical systems - 55 Alternator - 301 Alternator - Detailed view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Alternator - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Alternator - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Alternator - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Alternator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Alternator - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Alternator - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Alternator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Alternator - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Alternator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alternator Regulator - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

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Electrical systems - 55 Battery - 302

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Battery Problem solving (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Electrical systems - Battery

Battery - General specification Specifications Capacity (Amperes per hour in 20 hours) Intensity on starting (cold engine) Voltage Elements Mass Terminal

100 AÂˇh 750 A 12 V 6 Negative

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Electrical systems - Battery

Battery - Dynamic description Description and operation All the tractor models incorporate a 12 V volt battery with negative to ground. NOTE: 'Without maintenance' means that under normal conditions, the battery does not lose water from the electrolyte. There could be water losses under certain conditions, such as in a prolonged charge at over 14.4 V, giving rise to the production of gasses when full charge is attained. This could be caused by a defect in the charging system or by the rapid charge equipment. The battery is installed in the front part of the tractor, between the engine radiator and the front counterweight support. The batteries have three main functions: â&#x20AC;˘ Provide a source of electrical current for starting, lights and instruments. â&#x20AC;˘ Help to maintain control of voltage in the electrical installation. â&#x20AC;˘ Supply electrical current when the demand exceeds the alternator capacity. The battery is manufactured in such a way that each element contains positive and negative plates disposed alternately one next to the other. Each positive plate is separated from the negative plate by a porous and non-conductor separator. If a positive plate makes contact with a negative plate inside the element, it will go into short-circuit and be damaged beyond repair. All positive plates are welded to a bar, forming a positive terminal and the negative plates are welded to another similar bar that forms the negative terminal. Each positive plate comprises a lead grid with lead peroxide stuck between the grid openings. The negative plates comprise a grid with spongy lead stuck to the grid openings. The plates are immersed in a solution of diluted sulphuric acid liquid electrolyte.

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Electrical systems - Battery

Battery - Remove Battery 1. Raise the engine hood. 2. Disconnect the cable (1) negative (mass) of the battery 3. Remove the manual nuts (butterfly) from the battery fixation plate, and remove the plate. 4. Disconnect the positive (+) battery cable. 5. By hand, lift and take the battery out.

LAIL11TS0002A0A

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Electrical systems - Battery

Battery - Install Assembly 1. Battery installation will be done in accordance with the dismounting procedures, but in the reverse order, taking the following into account: • Check if the battery is clean and dry and if all the stoppers are in place. • Lubricate terminals with Vaseline petroleum jelly. Do not use conventional grease that can cause electrolytic corrosion. • Check if the battery installation location is clean and free of stones or objects that can damage the battery. • Make sure the battery terminal polarity is correct and the terminal connections are well, but not excessively tightened.

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Electrical systems - Battery

Battery - Charging Dry batteries 1. Remove the plug seals from the dry battery. 2. Fill each element to the recommended level with electrolyte at a density of 1260. Dry batteries must be prepared for use as follows: NOTE: The electrolyte should be diluted in sulphuric acid, preferably at a temperature between 21 - 31 Â°C 3. After filling the elements, allow the battery to settle for 15 minutes. When this time has elapsed, check the electrolyte level again and, if necessary, top it up. 4. Charge the battery for 4 h at 5 - 8 A and check to see if the gases escape freely from the elements. 5. Apply the battery plug seals to the battery.

Battery Charge Before charging the battery: 1. Thoroughly clean the battery housing and the element covers with ammonia or hot water and clean the terminals. 2. Check the electrolyte level in each element and, if it is below the plates, add distilled water until the plates are immersed.

Normal Charge With a slow charger, apply a load current of 3 - 6 A for as long as it takes for the battery to be fully charged. This may take more than 36 h if the battery is very flat. An extremely sulphated battery can not receive charge. When the battery is fully charged, the elements release gas freely and the relative density remains constant. Switch off the charger after having checked three consecutive times, at hourly intervals, that the density checked on the densitometer is no longer increasing. 3. When a battery is charged by the rapid charge method, the charger manufacturer's instructions should be followed particularly carefully. Rapid charging increases the temperature of the electrolyte, and if the charger is not fitted with an automatic timer or temperature regulator, the temperature of the electrolyte could rise to above 50 Â°C, leading to possible violent gasification in the battery and subsequent damage. 4. Check the electrolyte level in each element again and if necessary, top up the level with distilled water. NOTE: When a battery is being charged it produces explosive gases. Do not smoke or use naked flames when checking the electrolyte level and make sure the charger is switched off before turning any component on and off to avoid sparks and the possibility of explosion.

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Electrical systems - Battery

Recharging totally depleted batteries The method recommended for charging a Pb-Ca battery without maintenance is to use a constant voltage charger. Greatly depleted batteries require a charging period from 48 h to 16 V with a current limitation ( 47.5 A to 70 AÂˇh). This system is regulated automatically: high current is initially applied (when the battery voltage is low) and when the battery reaches full charge (and its voltage is high), the drawn current is progressively lowered. Where only constant current chargers are available, the levels and durations indicated in Table 2 are recommended. The values indicated in the table apply to batteries that are extremely depleted. If the battery is only 50 % charged, the indicated times must be reduced by half (slow charge programs). For other battery charge statuses, reduce the charging time proportionally. Whenever possible, use the slower charge program to increase the life of the battery. Where violent gasification or expulsion of the electrolyte is observed, the battery will be hot ( 50 Â°C or more). Temporarily reduce or suspend charging to prevent damage to the battery. Table 2 Slow charging programs Quick Recharge Program (only in emergency)

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Type of battery 100 AÂˇh (750 cca) 25 h to 5 A 12.5 h to 10 A 7 h to 18 A

Electrical systems - Battery

Battery - Preliminary test Tests Before starting battery tests, check the battery to make sure that the stoppers are not dirty, corroded, open and that the box is not damaged. Equipment required for tests: • Densimeter • Appliance for checking batteries (Checking high discharge) • Thermometer • Battery charger.

Density: This test determines the battery charge status. 1. With the buoy in the vertical position take the reading. 2. Adjust the densimeter readouts for the electrolyte temperature variations subtracting 4 points (density of 0.004) for every 5.5 °C below the temperature value to which the densimeter is calibrated and adding 4 points (density of 0.004) for every 5.5 °C above this value. The following examples are calculated for a densimeter calibrated to 30 °C. Example 1: Temperature below Electrolyte temperature Reading on densimeter Subtract 11.0 x 0.004 5.5 =1.262 Corrected density Example 2: Temperature over Electrolyte temperature Densimeter readout Add 10.0 x 0.004 5.5 =1.227 Corrected density

30 °C 19 °C 1.270 0.008

30 °C 40 °C 1.220 0.007

3. Use the table below to determine the battery charge status. Charge Status

Corrected density @ 15 °C

Corrected density @ 25 °C

100 % 75 % 50 % 25 % 0%

1.295 1.253 1.217 1.177 1.137

1.287 1.246 1.210 1.170 1.130

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Average battery voltage (Volts) 12.76 V 12.52 V 12.30 V 12.06 V 11.84 V

Electrical systems - Battery

NOTE: The variation in density between each of the elements must not be higher than 0.025. 4. If the density readout is 1.280 or higher, the battery is fully charged and in a good state. 5. If the corrected density is below 1.280, charge the battery and inspect the charging system to determine the reasons for the low battery charge. NOTE: If distilled water has recently been added, the battery should be recharged for a short period, because under these conditions, correct readings will not be obtained on the densimeter without recharge. If charging has been done with the battery always at rest, the electrolyte accumulated in the bottom of each element becomes denser. The battery must therefore be shaken during charge to mix the electrolyte and thus, improve not only the charging rate but also obtain more exact readings on the densimeter at the height of the battery tests.

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Electrical systems - Battery

Battery - Electrical test Performance tests Performance tests determine whether the battery had adequate capacity for starting the engine. The voltage reading obtained is used to determine the state of the battery. Before the tests, check whether the electrolyte level is correct and if the circuit voltage is 12.5 V or higher. The tests can be performed with the battery installed in the tractor. 1. Put the current control switch of the battery verifier appliance (high discharge verifier) in the off position and the voltage at a value equal to or slightly higher than the nominal voltage of the battery. Connect the positive appliance wires to the positive terminal on the battery and the negative wires to the negative battery terminal. 2. Turn the current control button up to the point at which the readout value on the amp meter is half of the value of the nominal battery CCA intensity, and at this point, measure the voltage. â&#x20AC;˘ If the reading is equal to or above 9.6 V volts after 15 s seconds the battery has an acceptable output capacity and will accept a normal charge well. However, if the measured voltage is lower than 9.6 V, the battery is not in operational condition and its charge must be tested as indicated below. NOTE: Do not leave discharge on the battery for more than 15 s.

Charge tests These tests were prepared only for batteries that fail the previous capacity tests. 1. Connect the battery verification appliance (high discharge verification) to the positive cables of the appliance on the positive battery terminal and the negative tables on the negative terminal. 2. Connect the charger positive and negative cables respectively to the positive and negative battery terminals. 3. Turn the charger timer to beyond the " 3 min" charge indication and then back again to the " 3 min" mark. 4. Set the charge rate as close as possible to 40 A. 5. After 3 min of quick charge, take the voltage reading on the voltmeter. If the total voltage is above 15.5 V volts the battery is in a poor state, probably sulphated or worn, and must be replaced.

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Electrical systems - Battery

NOTE: A slightly sulphated battery can be recovered with a multiple type battery charger with a maximum voltage in interrupted circuit limited to 50 V. Due to the high resistance of the sulphated battery, it is necessary to have a very high voltage in the beginning to overcome the sulphation resistance, and at first there may be no signs of acceptance of the charge. However, at the end of a few minutes of inactivity, a slight charge may be observed, followed by a rapid increase in charge. The charge must not be higher than 14 A and the battery temperature must not exceed 50 Â°C. When the intensity has been stably re-established regulate the voltage again until the charge rate is maintained at 5 A. Continue with this charge rate until the electrolyte density ceases to increase and remains at the approximate value of 1275-1278 at 20 Â°C which could last for up to 48 h of charging. Leave the battery at rest for 24 h and then perform the capacity tests previously described. â&#x20AC;˘ If the voltage is below 15.5 V, measure the density in each element and charge the battery again, according to the following scale: Density 1150 or less 1151 to 1175 1176 to 1200 1201 to 1225

Rapid charge at: 60 min 45 min 30 min ( 15 min slow charge only)

NOTE: When problems with the battery are observed, one must first check the fan belt tightening tension and the battery charging system.

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Electrical systems - Battery

Battery - Test Maintenance and battery test Density The electrolyte relative density of the battery indicates the charge status. When the battery is fully charged the electrolyte density is a minimum of 1280 at 25 °C. Alternatively, it is possible to measure the approximate state of battery charge using a digital voltmeter with good precision ( ±0.10 V): Below 10.5 V, the battery is out of service* Below 11.8 V, the battery is not charged Below 12.3 V, the battery is at half charge Above 12.6 V, the battery is fully charged *Consult the notes under the title "Tests" as regard the possibility of recovering a slightly sulphitated battery. The battery voltage must be taken with the battery disconnected from the installation and: 1. four hours following disconnection from the installation and remain at rest during this time. 2. If the vehicle is left in operation, or the battery has been charged recently, switch on the headlamps for two minutes. When the battery goes flat, the sulphuric acid in the electrolyte combines chemically with the plates, which lowers the solution relative density. A battery densitometer determines the density of the electrolyte in each element and the amount of sulphuric acid not used in the solution is the measure of the degree of charge in this element. The lower the ambient temperature in which the battery will operate, the greater the need to keep the fully charged status. For example, a battery with a low density of 1225 at 27 °C could make a starter motor work at a high ambient temperature, but not at low temperatures, because they diminish its efficiency. Table 1 shows the effect of temperature on the efficiency of a normal battery. Temperature (°C) 25.0 °C -4.5 °C -24.0 °C -27.5 °C -31.0 °C -34.5 °C -37.5 °C

Efficiency of a charged battery 100 % 82 % 64 % 58 % 50 % 40 % 33 %

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Electrical systems - Battery

The maximum duration of the battery can be obtained when the battery is periodically inspected and the correct maintenance service effected. It is important for the production capacity not to be exceeded by operating the battery at constant and excessive overloads, and that the charging requirements are observed. NOTE: The batteries contain sulphuric acid and during charging they produce a highly explosive mixture of hydrogen and oxygen gasses. â&#x20AC;˘ Never use any equipment that produces flames or sparks to check the electrolyte level. â&#x20AC;˘ Do not remove the battery stoppers without hand and eye protection. When servicing the battery, follow these procedures: 1. Keep the electrolyte at the recommended level of 17 mm above the plates. 2. Use only distilled or mineral free water, do not overfill and never use tap water or rain water or from any other source. 3. Always keep the battery charged to at least 75 %, otherwise the plates get sulphated and there will be a loss of performance with possible damage due to freezing at low temperatures. 4. Avoid overcharging the battery so as not to cause heat inside it, which in turn will damage the plate grids and cause loss of water. 5. During quick charge make sure the battery temperature does not exceed 50 Â°C.

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Electrical systems - Battery

Battery - Problem solving 7630 8030

LA LA

OPERATION 1. Broken circuit within the battery 2. Short circuit within the battery. 3. Electrolyte loss 4. Separation of the active material through the grid. 5. The accumulation of sulphate crystals significantly impedes dispersal. These faults are normally caused by the following: 1. Damage to internal element components. 2. Excessive formation of crystals that could have punctured the separators and caused short circuits. 3. Excessive charging (the charging system is less effective, incorrect procedures when performing quick charges at high voltage, operating at extremely high temperatures). 4. The electrolyte in a fully charged battery will only freeze at —65 °C ; within a battery with 50 % of charge, it will freeze between –17 - –27 °C, and within a completely depleted battery, it will freeze at –3 - –11 °C. 5. Crystal formation occurs as batteries deplete. This condition is aggravated by high temperatures and lengthy periods of discharge. At ambient temperature and at the end of a week, it is improbable that the battery can be recovered in the vehicle. Recharging requires constant high voltage. At the end of 3 weeks, the battery will suffer permanent degradation and the above mentioned charging procedures described in ‘Recharging totally depleted batteries’ should be followed. When fully charged, batteries last longer. Lead calcium batteries discharge at a rate of 3 % per month. This means that it would take 16 months to reach 50 % of charge. In the tractor, the charge at rest is 50 mA. To prevent discharge within a stationary vehicle, approximately 8 A·h should be added weekly. It is important to stress that should a battery begin to fail on start-up, it is better to stop and wait a few minutes until the battery recovers. The time spent waiting for the battery to recover should be increased in proportion to the prevailing reduction in temperature. In installations with two batteries, an old battery must not be used with a new one. There will always be one battery that fails first. If the battery that failed has reached the expected length of use, replace both batteries. If one of the batteries fails sooner than it should, this will be due to a manufacturing defect and it would be fine to replace just this battery. TROUBLESHOOTING NOTE:

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Index Electrical systems - 55 Battery - 302 Battery - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Battery - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Battery - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Battery - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Battery - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Battery - Problem solving (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Battery - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

(*) See content for specific models 73403953 04/04/2014

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Electrical systems - 55 Engine cooling system - 012

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Engine cooling system - 012

FUNCTIONAL DATA Engine coolant temperature sensor Dynamic description of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Dynamic description of the sensor It is a component that integrates the temperature sensor. It is mounted in the poppet near the thermostat body and has the function of measuring the temperature of the engine coolant. Working temperature range: Connector side: 40 - 130 °C ( 150 °C for periods of less than 10 min) Engine bulb side: 40 - 140 °C Working voltage: 6 - 28 V Calibrations: A 80 °C: 0.304 — 0.342 kΩ. A 20 °C: 2.262— 2.760 kΩ. A -10 °C: 8.244 — 10.661 kΩ.

BRAG11TR0135LUE

BRAG11TR0167LUE

KSB water temperature sensor It is positioned on the poppet on the left-hand side of the engine. Characteristics: Working tension: 12 - 24 V. Electrical load: 2.5 A (inductive) 5.0 A (resistive) Inflation Opening contacts with increasing temperature: 66 °C.

60 -

Closing contacts with decreasing temperature: 50 - 56 °C.

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Dynamic description of the sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 Engine oil system - 013

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil pressure and temperature sensor Engine oil pressure and temperature sensor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 73403953 04/04/2014

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Electrical systems - Engine oil system

Engine oil pressure and temperature sensor - Dynamic description 7630 8030

LA LA

It is fitted on the block on the left side of the engine Characteristics: Working tension: 12 - 24 V. Contacts close by a fall in pressure: 0.6 bar. Contacts open by a rise in pressure: 0.9 bar.

BRAG11TR0168LUE

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure and temperature sensor - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

(*) See content for specific models 73403953 04/04/2014

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Electrical systems - 55 Ground speed control - 610

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Ground speed control - 610

FUNCTIONAL DATA Ground speed control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Ground speed control Ground speed control - Remove - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Inspect - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Test - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - Ground speed control

Ground speed control - Overview Inverter lock mechanism The transmission has an inverter lock mechanism installed on the upper cover of the transmission. The mechanism mechanically prevents the inversion of the tractor movement direction without the clutch pedal being fully depressed. By pressing the clutch pedal (1), the cable moves the lock rod and allows the inverter assembly to move.

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Electrical systems - Ground speed control

Ground speed control - Remove - Neutral (safety) start switch CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

WARNING Battery gas can explode! To prevent an explosion: 1. Always disconnect the negative (-) battery cable first. 2. Always connect the negative (-) battery cable last. 3. Do not short circuit the battery posts with metal objects. 4. Do not weld, grind, or smoke near a battery. Failure to comply could result in death or serious injury. W0011A

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Electrical systems - Ground speed control

Ground speed control - Inspect - Neutral (safety) start switch WARNING Maintenance hazard! Before performing any maintenance or inspection: -position machine on a firm, level surface -turn off the engine -remove the ignition key -secure the machine (wheels chocked) -disconnect the wiring (unless instructed otherwise) Failure to comply could result in death or serious injury. W1071A

Prior operation: Ground speed control - Remove - Neutral (safety) start switch (55.610) Inspect the switch for damage or wear. needed.

Replace as

Next operation: Ground speed control - Install - Neutral (safety) start switch (55.610)

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Electrical systems - Ground speed control

Ground speed control - Install - Neutral (safety) start switch Prior operation: Ground speed control - Remove - Neutral (safety) start switch (55.610) Prior operation: Ground speed control - Inspect - Neutral (safety) start switch (55.610) 1. Connect the neutral start switch wires to the switch. 2. Secure the shift cover to the transmission housing. 3. Connect the connector for the neutral start switch to the wire harness. Next operation: Ground speed control - Test - Neutral (safety) start switch (55.610)

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Electrical systems - Ground speed control

Ground speed control - Test - Neutral (safety) start switch Prior operation: Ground speed control - Install - Neutral (safety) start switch (55.610) 1. Connect a test bulb in series with the switch terminals and the battery. 2. Move the switch actuator housing along the high/low shift rail and away from the center line of the actuator bolt. 3. The test bulb should illuminate only when the actuator housing is centered over the actuator bolt. NOTICE: Do not move the actuator housing more than 6 mm (0.24 in) from the center line of the actuator bolt to prevent the bolt from jumping out of the shift rail.

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Electrical systems - Ground speed control

Ground speed control - Electrical test Inspecting the neutral start switch 1. Inspect the switch rod conical tips for any cuts and burrs. If any of these anomalies cannot be eliminated by slight polishing, fit a new rod. 2. Use a multimeter to test the continuity with the switch open and discontinuity with the switch closed (neutral). If no appropriate piece of equipment is available, test using a lamp, Figure 1. 3. The lamp should go on and off when the switch is operated. Replace the switch if it does not work correctly.

LAIL11TS0415A0A

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Electrical systems - Ground speed control

Ground speed control - Travel adjust Adjustment In order to ensure correct operation of the lock, adjust the cable with the adjustment nuts (3) so that the end of the cable (5) moves 6 - 8 mm when the clutch pedal is fully depressed.

LAIL11TS0620A0A

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Index Electrical systems - 55 Ground speed control - 610 Ground speed control - Remove - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Ground speed control - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ground speed control - Inspect - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Ground speed control - Install - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Ground speed control - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ground speed control - Test - Neutral (safety) start switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Ground speed control - Travel adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Electrical systems - 55 Service brake electrical system - 030

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 Service brake electrical system - 030

SERVICE Service brake electrical system Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Service brake electrical system

Service brake electrical system - Adjust Adjusting the brake pedal switches Place a 2.5 mm (0.10 in) thick bar between the switch and the brake pedal. Loosen the screws that fasten the switch. Push the switch toward the brake pedal up to the cylinder travel limit making sure at the same time that the pedal stays still. Tighten the fastening bolts and remove the bar. Repeat this operation with the other switch. After this adjustment, make sure that you can be hear both switches working and that they operate simultaneously.

LAIL11TS0230A0A

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Index Electrical systems - 55 Service brake electrical system - 030 Service brake electrical system - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - 55 External lighting - 404

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 External lighting - 404

FUNCTIONAL DATA External lighting External lighting - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE External lighting Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Headlight Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Work light Rear - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - External lighting

External lighting - Component localisation The tractors have front head lights (1), located on the hood of the engine, and an auxiliary service light, located on the rear right mudguard (2).

LAIL11TS0156A0A

LAIL11TS0157A0A

The signaling light and brake light (3) are also installed on the mudguards. NOTICE: The following information in this section is provided as a fast reference guide and is not intended to be considered as a substitute for the detailed operating information that appears in the Operator's Manual. For further details on the use of controls and checking the instruments and warning lights, read all of Section 2 in the Operator Manual before putting the tractor to work

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Electrical systems - External lighting

External lighting - Alignment Adjustments to the front headlamp and replacement bulbs Front Light To avoid blinding approaching traffic, adjust the beam angle of the front headlamps. Each headlamp is fixed on a three screw support with pressure springs (1) and (2). The beam can be adjusted vertically or laterally by turning each screw as necessary. To change a front headlamp, open the cover to access the rear part of the light.

LAIL11TS0156A0A

LAIL11TS0159A0A

NOTICE: All the headlamps have halogen bulbs. Never touch halogen bulb with your fingers. The natural humidity of fingers can burn the bulb when it is on. Use a clean cloth or towel to handle halogen bulbs. Remove the electrical connector (2) and then the rubber seal (3) from behind the bulb assembly. Disengage the retaining spring (1) and remove the bulb. Fit in reverse order.

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Electrical systems - External lighting

External lighting - Overhaul Work Lights To access the work lights, remove the 2 bolts (1) and remove the whole light assembly from its housing. Free the spring and remove the bulb from the reflector assembly. NOTICE: All work lights have halogen bulbs. Never touch halogen bulb with your fingers. The natural humidity of fingers can burn the bulb when it is on. Use a clean cloth or towel to handle halogen bulbs.

LAIL11TS0160A0A

LAIL11TS0157A0A

Brake lights/conversion lights and rear lights Although there are different models of front and rear lights for different markets, access to their bulbs is always as described in the following text. All brake lights/conversion lights/rear lights can be accessed after removing the plastic lens. The lens is fitted to the light body using bolts (1). The bulbs have a conventional bayonet-type socket and can by removed by pressing in and turning approximately 20Â° to the left. NOTICE: When replacing the lens, take care not to overtighten the fixing bolts.

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Electrical systems - External lighting

Headlight - Alignment Headlight adjustments and bulb replacements Front Headlights In order not to blind the drivers of oncoming traffic, adjust the beam angle of the front headlights. Each headlight is fixed on the support by three screws with pressure springs (1) and (2). The light beam can be adjusted vertically or sideways, turning one or the other screw, as necessary. To change a front headlight bulb, open the hood to gain access to the back part of the light.

LAIL11TS0156A0A

LAIL11TS0159A0A

NOTICE: All the headlights have halogen bulbs. Never touch a halogen bulb with your fingers. The natural humidity of the fingers can burn the bulb when it is on. Use a clean cloth or handkerchief to handle halogen bulbs. Remove the electrical connector (2) and then the rubber cover (3) from the back part of the bulb set. Unhook the retaining spring (1) and remove the bulb. Mount in the inverted order.

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Electrical systems - External lighting

Work light Rear - Overhaul Working lights To have access to the working light bulb, remove the two bolts (1) and remove the complete light assembly from its housing. Free the spring and remove the bulb from the reflector assembly. NOTICE: All the work lights have halogen bulbs. Never touch a halogen bulb with your fingers. The natural humidity of the fingers can burn the bulb when it is on. Use a clean cloth or handkerchief to handle halogen bulbs.

LAIL11TS0160A0A

LAIL11TS0157A0A

Brake lights/turning lights and tail lights Although there are different models of front and rear lights for the different markets, the access to the bulbs is the same as described in the following text. All the brake lights/turning lights/tail lights can be accessed after removing the plastic lens. The lens is fixed to the light body by means of bolts (1). The bulbs have a conventional bayonet type socket and can be removed by pressing on them and turning approximately 20Â° to the left. NOTICE: When replacing the lens, take care not to over tighten the fixation bolts.

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Index Electrical systems - 55 External lighting - 404 External lighting - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 External lighting - Component localisation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 External lighting - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Headlight - Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Work light Rear - Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - 55 External lighting switches and relays - 405

7630 [Z7CA27168 - ] 8030 [Z7CA27168 - ]

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Contents Electrical systems - 55 External lighting switches and relays - 405

FUNCTIONAL DATA Headlight switch Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - External lighting switches and relays

Headlight switch - Overview Headlight switch connectors Are located on the bottom right side of the instrument panel. It has 4 working positions: 1. Lights off 2. Instrument panel light and rear lights on 3. Low beam, tail light and rear headlight 4. High beam, tail light and rear headlight To remove it, disconnect the connectors on the back part of the key, remove the front fixation nut and push the key backwards. LAIL11TS0158A0A

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Index Electrical systems - 55 External lighting switches and relays - 405 Headlight switch - Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

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SCHEMAS INDEX Reference Wire Wire Wire Wire Wire Wire

harnesses harnesses harnesses harnesses harnesses harnesses

Electrical Electrical Electrical Electrical Electrical Electrical

schematic schematic schematic schematic schematic schematic

sheet sheet sheet sheet sheet sheet

01 02 03 04 05 06

PAGE 55.2 / 9 55.2 / 10 55.2 / 11 55.2 / 12 55.2 / 13 55.2 / 14

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SPECIAL TOOL INDEX Genuine 291182 [Water Pump Impeller And Steering Wheel Puller] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001003 [Square Complete For Checking Connecting Rods Perpendicular] 380001601 [Dial Indicator Extension Pin and Adapter] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000617 [Dummy Injector used in 4.5L & 6.7L (NEF)] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 291182 [Water Pump Impeller And Steering Wheel Puller] 380001601 [Dial Indicator Extension Pin and Adapter] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380000988 [Starter opening plate and Flywheel Rotation Blocker] 380001601 [Dial Indicator Extension Pin and Adapter] 380000255 [Differential Overhaul Support] 293952 [Torque Wrench] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000255 [Differential Overhaul Support] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket]

Reference

PAGE

Engine - Special tools

10.1 / 8

Engine - Special tools

10.1 / 8

Engine - Special tools

10.1 / 9

Engine - Special tools

10.1 / 9

Engine - Disassemble

10.1 / 16

Engine - Compression test

10.1 / 26

Engine flywheel - Assemble

10.6 / 5

Rotary injection pump - Remove

10.11 / 7

Rotary injection pump - Remove

10.11 / 8

Rotary injection pump - Timing adjust

10.11 / 9

Rotary injection pump - Install

10.11 / 11

Rotary injection pump - Check

10.11 / 12

Rotary injection pump - Check

10.11 / 13

Powered front axle - Disassemble

25.1 / 29

Differential lock Dog clutch - Dynamic description Bevel gear set and differential carrier - Preload

25.2 / 11 25.2 / 13

Bevel gear set and differential carrier - Preload

25.2 / 13

Bevel gear set and differential carrier - Preload

25.2 / 13

Bevel gear set and differential carrier - Preload

25.2 / 13

Bevel gear set and differential carrier - Preload

25.2 / 14

Bevel gear set and differential carrier - Preload

25.2 / 14

Bevel gear set and differential carrier - Preload

25.2 / 14

Bevel gear set and differential carrier - Preload

25.2 / 14

Bevel gear set and differential carrier - Preload

25.2 / 14

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Genuine 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000249 [Universal Pinion Installation Tool Kit] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000255 [Differential Overhaul Support] 380000252 [Front Axle Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000235 [Swivel Housing Torque Check Adapter] 380000235 [Swivel Housing Torque Check Adapter]

Reference

PAGE

Bevel gear set and differential carrier - Clearance

25.2 / 16

Bevel gear set and differential carrier - Clearance

25.2 / 16

Bevel gear set and differential carrier - Clearance

25.2 / 16

Bevel gear set and differential carrier - Clearance

25.2 / 16

Bevel gear set and differential carrier - Clearance

25.2 / 16

Bevel gear set and differential carrier - Clearance

25.2 / 16

Differential - Assemble

25.2 / 23

Differential - Assemble

25.2 / 24

Differential - Assemble

25.2 / 24

Differential - Assemble

25.2 / 24

Differential - Assemble

25.2 / 25

Differential - Assemble

25.2 / 25

Differential - Assemble

25.2 / 25

Differential - Disassemble

25.2 / 30

Differential - Disassemble

25.2 / 30

Differential - Disassemble

25.2 / 30

Differential - Disassemble

25.2 / 32

Differential - Disassemble

25.2 / 32

Differential - Disassemble

25.2 / 32

Steering knuckle and king pin - Replace

25.3 / 22

Steering knuckle and king pin - Replace

25.3 / 22

Steering knuckle and king pin - Replace

25.3 / 23

Steering knuckle and king pin - Replace

25.3 / 23

Steering knuckle and king pin - Replace

25.3 / 26

Steering knuckle and king pin - Replace

25.3 / 26

Steering knuckle and king pin - Adjust

25.3 / 27

Steering knuckle and king pin - Adjust

25.3 / 27

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Genuine FNH00705 [Straight Fitting - 7/16-20 UNF 37° x 1/4 F NPTF] FNH02028 [Pressure Gauge, 0-5000 PSI w/Male Disconnect] 380000583 [Tool For The Installation Of The Swing Axle Housing Universal Joint Seal ] FNH02028 [Pressure Gauge, 0-5000 PSI w/Male Disconnect] FNH00705 [Straight Fitting - 7/16-20 UNF 37° x 1/4 F NPTF] FNH00095 [Coupler Spanner Wrench] FNH00095 [Coupler Spanner Wrench] NHT-0507 [ADAPTERS TO PLACE AND REMOVE BUSHINGS FROM HYDRAULIC LIFT CONTROLLER VALVE] NHT-0506 [Special Tool] NHT-0502 [Special Tool] FT8527 [Control Linkage Rod And Roller Setting Gauge] NHT-0502 [Special Tool] NHT-0502 [Special Tool] FNH00014 [Hydraulic Power Lift Control Valve] FNH00014 [Hydraulic Power Lift Control Valve] NHT-0502 [Special Tool] NHT-0502 [Special Tool] FNH00014 [Hydraulic Power Lift Control Valve] FNH00014 [Hydraulic Power Lift Control Valve] 380000240 [Hydraulic Pressure Test Kit] 380000281 [Rotoglyd Steering Seal Installer]

OEM

Reference

PAGE

Hydraulic systems - Special tools

35.1 / 6

Hydraulic systems - Special tools

35.1 / 6

Hydraulic systems - Special tools

35.1 / 6

Hydraulic systems - Torque

35.1 / 6

Hydraulic systems - Torque

35.1 / 6

Remote control valve Closed center mechanical remote valve Special tools Remote control valve Closed center mechanical remote valve Special tools Hitch control valve - Special tools

35.5 / 4

35.6 / 3

Hitch control valve - Special tools Hitch control valve - Special tools Rear three-point hitch - Adjust

35.6 / 3 35.6 / 3 37.1 / 38

Rear three-point hitch - Adjust Rear three-point hitch - Adjust Rear three-point hitch - Adjust

37.1 / 43 37.1 / 43 37.1 / 43

Rear three-point hitch - Adjust

37.1 / 43

Rear three-point hitch - Adjust Rear three-point hitch - Adjust Rear three-point hitch - Adjust

37.1 / 44 37.1 / 44 37.1 / 44

Rear three-point hitch - Adjust

37.1 / 44

Hydraulic control components - Special tools

41.2 / 3

Hydraulic control components - Special tools

41.2 / 3

Reference

OEM1074 [Compression Engine - Compression test Gauge] OEM1459 [Pressure Gauge 0 Hydraulic systems - Special tools - 40 Bar (0 - 600 psi)]

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PAGE 10.1 / 26 35.1 / 6

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Av. Juscelino K. de Oliveira, 11825, CIC - Curitiba (PR) - Brasil, CEP:81170-901 SERVICE - Technical Publications & Tools

73403953 04/04/2014 EN