New Holland T4.55 T4.65 T4.75 PowerStar Tractor Service Manual (84419869A) - PDF Download by www.heydownloads.com

SERVICE MANUAL T4.55 / T4.65 / T4.75 PowerStar™ Tractor

Part number 84419869A English October 2011 Printed in U.S.A. Copyright © 2011 CNH America LLC. All Rights Reserved. New Holland is a registered trademark of CNH America LLC. Racine Wisconsin 53404 U.S.A.

INTRODUCTORY NOTES --

This manual is divided into sections identified by two--figure numbers and each section has independent page numbering.

The different sections can easily be found by consulting the table of contents on the following pages.

The document number of the manual and the edition/update dates are given at the bottom of each page.

The pages of future updates will be identified by the same print number followed by an additional digit: standard manual first edition 84419869A -- 1st update 84419869A1 -- 2nd update 84419869A2 -- etc. The pages of the update can replace or supplement the pages of the standard manual; the necessary information for the procedure to add or replace the pages is given on the title page of the update. The publication will be completed with an appropriate index. If it is necessary to issue a new updated manual (2nd edition) it will have document number 84419869B, this indicates that the manual is composed of the standard version 84419869A completed with all the updates: 1st update 84419869A1 -- 2nd update 84419869A2 -- etc.

The information contained in this manual was current on the date printed on each section. As NEW HOLLAND constantly improves its product range, some information may be out of date subsequent to modifications implemented for technical or commercial reasons, or to meet legal requirements in different countries. In the event of conflicting information, consult the NEW HOLLAND Sales and Service Departments.

IMPORTANT WARNINGS --

All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary.

Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.

The Manufacturer and all organisations belonging to the Manufacturerâ&#x20AC;&#x2122;s distribution network, including but not restricted to national, regional or local distributors, will accept no responsibility for personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer, including those used for maintenance and/or repair of the product manufactured or marketed by the Manufacturer. In any case, the product manufactured or marketed by the Manufacturer is covered by no guarantee of any kind against personal injury or damage to property caused by abnormal function of parts and/or components not approved by the Manufacturer.

No part of the text or illustrations may be copied

PRINTED IN FRANCE ďŁŠ CNH GLOBAL N.V.

Print no. 84419869A -- 06 -- 2011

CONTENTS

CONTENTS Page

Date

00 -- GENERAL GUIDELINES

Page

Date

21 -- GEAR TRANSMISSION

General instructions . . . . . 1--2

06--11

Safety regulations . . . . . . . 3--4--5

06--11

Chapter 1 -- Mechanical transmission

Tractor refuelling . . . . . . . . 6

06--11

Main Data . . . . . . . . . . . . . . 1--2

06--11

Torque Specifications . . . . 2--3

06--11

10 -- ENGINE

Tools . . . . . . . . . . . . . . . . . . 4

06--11

CHAPTER 1

Sections . . . . . . . . . . . . . . . 5--6--7

06--11 06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Description and operation

General specifications

06--11

Troubleshooting . . . . . . . . . 8--9

06--11

Removal--Installation -rear transmission -- gearbox casing . . . . . . . . . . . . . . 10--11--12-13

06--11

Disassembly--Assembly -transmission--gearbox casing . . . . . . . . . . . . . . . . . . . 17--18

06--11

Disassembly--Assembly -clutch casing . . . . . . . . . . . . 19--20--21

06--11

Sealing compound application diagram . . . . . . . . . . . . 22

06--11 06--11

2--3

Engine removal--installation . . . . . . . . . . . . . . . . . . . . 4--5--6--7--8 --9--10 Removal--Installation fuel tank . . . . . . . . . . . . . . . . . . . 11--12

06--11

Coolant radiator removal-installation . . . . . . . . . . . . . . 13--14--15

06--11

Accelerator control cable adjustment . . . . . . . . . . . . . 16

06--11

18 -- CLUTCH

Main Data . . . . . . . . . . . . . . 1

06--11

Transmission oil cooler removal--installation . . . . . . . 23

Torque Specifications . . . . 2

06--11

CHAPTER 3 -- Power Shuttle transmission

Tools . . . . . . . . . . . . . . . . . . 2

06--11

Main Data . . . . . . . . . . . . . . 1--2

06--11

Sections . . . . . . . . . . . . . . . 3

06--11

Torque Specifications . . . . 3

06--11

Troubleshooting . . . . . . . . . 4

06--11

Tools . . . . . . . . . . . . . . . . . . 4

06--11

Removal--Installation -clutch . . . . . . . . . . . . . . . . . . 5

06--11

Sections . . . . . . . . . . . . . . . 5--6--7

06--11

Clutch Overhaul . . . . . . . . . 6--7--8--9

06--11

Description and operation . 8

06--11

Checks and measurements -- clutch . . . . . . . . . . 10--11

Troubleshooting . . . . . . . . . 8

06--11

Adjustments -- clutch disengagement levers . . . . . . . . 11

Disassembly--Assembly -clutch casing . . . . . . . . . . . . 9--10--11

06--11

Main clutch adjustments . . 12

06--11

Adjustments -- clutch pedal . . . . . . . . . . . . . . . . . . . . . . . . 12

06--11

23 -- DRIVE LINES

Sectional view of PTO clutch servo control . . . . . . 13

06--11

Description and operation of PTO servo control . . . . . 14--15

06--11

PTO servo control adjustment . . . . . . . . . . . . . . . . . . . 16 PTO engaged switch adjustment . . . . . . . . . . . . . . . . 17

Main Data . . . . . . . . . . . . . . 1

06--11

Torque Specifications . . . . 2

06--11

Sections . . . . . . . . . . . . . . . 3--4

06--11

Description and operation . 5

06--11

Troubleshooting . . . . . . . . . 6

06--11

Drive shafts and guard. Disassembly -- Assembly . . . 7

06--11

84419869A -- 06 -- 2011

CONTENTS

4 Page Removal--Installation -- drive gear casing . . . . . . . . . . 8

Date 06--11

25 -- FRONT AXLE MECHANICAL TRANSMISSION CHAPTER 1 -- Front mechanical transmission Main Data . . . . . . . . . . . . . . 1--2

06--11

Torque Specifications . . . . 3--4

06--11

Tools . . . . . . . . . . . . . . . . . . 5

06--11

Sections . . . . . . . . . . . . . . . 6

06--11

Removal--Installation -front axle . . . . . . . . . . . . . . . 8--9--10

06--11

Front axle. Disassembly -Assembly . . . . . . . . . . . . . . 11--12--13-14--15--16-17--18

06--11

Replacing steering knuckle pins and bearings . . . . . . . 19

06--11

Adjustments -- steering knuckle bearings . . . . . . . . 20--21

06--11

Adjustments -- bevel drive

Page

Date

14--15--16

06--11

Removal -- Installation side gear casing . . . . . . . . . 17--18--19-20

06--11

Disassembly--Assembly -drive wheel shaft . . . . . . . . 21--22

06--11

31 -- POWER TAKE--OFF CHAPTER 1 -- Mechanical power take--off Main Data . . . . . . . . . . . . . . 1--2

06--11

Torque Specifications . . . . 3--4

06--11

Sections . . . . . . . . . . . . . . . 5--6

06--11

Description and operation . 7--8

06--11

Troubleshooting . . . . . . . . . 8

06--11

33 -- BRAKES Main Data . . . . . . . . . . . . . . 1--2

06--11

Torque Specifications . . . . 2

06--11

Sections . . . . . . . . . . . . . . . 3

06--11

Description and operation . 4

06--11

Troubleshooting . . . . . . . . . 5--6

06--11

Overhaul -- front differential 29

06--11

LIM--SLIP self--locking differential . . . . . . . . . . . . . . . . 30--31

Removal--Installation -- service brake . . . . . . . . . . . . . . 7

06--11

Checking leading wheel alignment . . . . . . . . . . . . . . 32

Removal--Installation -- service brake pump . . . . . . . . . 8--9

06--11

Disassembly--Assembly -front epicyclic final drive . . 33--34

Adjustments -- service brake pedals travel . . . . . . . . . 10

06--11

Service brake circuit air bleeding . . . . . . . . . . . . . . . . 11--12

06--11

Adjustments -- bevel drive

22--23--24-25--26--27-28

27 -- REAR MECHANICAL TRANSMISSION Main Data . . . . . . . . . . . . . . 1--2

06--11

Torque Specifications . . . . 3--4

06--11

Tools . . . . . . . . . . . . . . . . . . 5

06--11

Sections . . . . . . . . . . . . . . . 6--7

06--11

Description and operation . 8

06--11

Troubleshooting . . . . . . . . . 8

06--11

Disassembly--Assembly -transmission--gearbox casing . . . . . . . . . . . . . . . . . . . 9--10--11-12 Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 13 84419869A -- 06 -- 2011

35 -- HYDRAULIC SYSTEMS CHAPTER 1 -- Rear mechanical hydraulic lift Main Data . . . . . . . . . . . . . . 2

06--11

Torque Specifications . . . . 2--3

06--11

Tools . . . . . . . . . . . . . . . . . . 3

06--11

Sections . . . . . . . . . . . . . . . 4

06--11

Troubleshooting . . . . . . . . . 5

06--11

Description and operation . 6--7--8--9-10--11

06--11

Lift internal controls. Disassembly -- Assembly . . . . . . 12--13--14-15

06--11

CONTENTS Page

Date

Draft reading unit Disassembly -- Assembly . . . . . . 16--17

06--11

Lift arms shaft. Disassembly -- Assembly . . . . . . . . . . 18--19

06--11

Removal--Installation -- lift control valve . . . . . . . . . . . . 20

06--11

Adjusting the lift . . . . . . . . . 21--22--23

06--11

CHAPTER 2 -- Open centre system auxiliary control valves

5 Page

Date

Bucket control cylinder removal--installation . . . . . . . 15

06--11

Replacement of pins . . . . . 16

06--11

41 -- STEERING CHAPTER 1 -- Steering Main Data . . . . . . . . . . . . . . 2

06--11

Torque Specifications . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . 3

06--11

Description and operation . 4--5--6

06--11

Main Data . . . . . . . . . . . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . 2

06--11

Torque Specifications . . . . 2

06--11

View of hydrostatic steering control valve components . 7

06--11

Sections . . . . . . . . . . . . . . . 3--4

06--11

Troubleshooting . . . . . . . . . 8--9

06--11

Description and operation . 5--6--7--8

06--11

Auxiliary control valves. Disassembly -- Assembly . . . 9--10--11

Replacement -- hydrostatic steering wheel . . . . . . . . . . 10

06--11

CHAPTER 3 -- Trailer brakes auxiliary control valves Sections . . . . . . . . . . . . . . . 1

06--11

Description and operation . 1--2--3--4--5 --6--7

06--11

Troubleshooting . . . . . . . . . 8--9--10

06--11

CHAPTER 8 -- Front Loader

Removal--Installation -- hydrostatic steering control 11--12 valve . . . . . . . . . . . . . . . . . .

06--11

Disassembly--Assembly -hydrostatic control valve . . 13--14--15-16--17--18-19--20--21-22--23--24-25--26--27-28

06--11

Main Data . . . . . . . . . . . . . . 1

06--11

Hydrostatic steering control valve bench testing . . . . . . 29--30

06--11

Sections . . . . . . . . . . . . . . . 2

06--11

Pressure relief valve testing 31

06--11

Torque Specifications . . . . 3

06--11

Troubleshooting . . . . . . . . . 4--5

06--11

Steering control cylinder. Removal -- Installation . . . . 32--33

06--11

Parking the front loader . . . 6

06--11

Front loader arm connection bracket Removal--Installation . . . . . . . . . . . . . . . 7

Steering control cylinder. Disassembly--Assembly . . 34--35

06--11

Replacement of control struts (mod. MSL) . . . . . . . 8

06--11

Replacement of triangular articulation levers (mod. MSL) . . . . . . . . . . . . . . . . . . 9

06--11

Bucket support device removal--installation . . . . . . . 10

06--11

Position indicator disassembly--assembly . . . . . . . 11

06--11

Bushing replacement . . . . 12--13

06--11

Loader cylinder removal-installation . . . . . . . . . . . . . . 14

06--11

50 -- CAB HVAC SYSTEM Safety regulations . . . . . . . 2

06--11

Main Data . . . . . . . . . . . . . . 3

06--11

Tools . . . . . . . . . . . . . . . . . . 4

06--11

Operating principles . . . . . 5

06--11

Conditioning system components . . . . . . . . . . . . . . . . 6--7--8--9-10

06--11

Cab controls . . . . . . . . . . . . 11--12--13

06--11

Testing operation and cooling . . . . . . . . . . . . . . . . . . . . 14--15

06--11

84419869A -- 06 -- 2011

CONTENTS

6 Page Air conditioning system maintenance . . . . . . . . . . . . 16--17

06--11

Troubleshooting . . . . . . . . . 18--19--20-21

06--11

Refrigerant recovery--recycling and evacuation--charging stations . . . . . . . . . . . . 22--23

Page

Date

System testing . . . . . . . . . . 8÷10

06--11

Starter motor removal--installation . . . . . . . . . . . . . . . 11÷13

06--11

CHAPTER 3 -- Charging system 06--11

Dehydration, recharging and refrigeration check . . . 24--25--26-27--28--29-30

06--11

Checking for and eliminating any gas leaks . . . . . . . 31--32

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Technical data . . . . . . . . . . 2

06--11

Torque Specifications . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . . 3

06--11

Description and operation . 3--4

06--11

System testing . . . . . . . . . . 5

06--11

Belt Tension . . . . . . . . . . . . . 6

06--11 06--11

Cab heating/air--conditioning system. Removal -- Installation . . . . . . . . . . . . . . . 33--34

06--11

Alternator motor removal and installation . . . . . . . . . . 7--8

Cab electric fan unit. Disassembly -- Assembly . . . . . . 35

06--11

CHAPTER 4 -- Battery

Air--conditioning system condenser removal--installation . . . . . . . . . . . . . . . . . . 36

Date

06--11

55 -- ELECTRICAL SYSTEM CHAPTER 1 -- Instruments

Summary . . . . . . . . . . . . . . . 1

06--11

Technical data . . . . . . . . . . 2

06--11

Description and operation . 2

06--11

Battery removal and installation . . . . . . . . . . . . . . . . . . 3

06--11

Battery testing and charging procedure . . . . . . . . . . 4÷14

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Digital analog instrument

06--11

Speedometer/tachometer . 3

06--11

LCD panel settings . . . . . . 3÷7

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Coolant temperature . . . . . 7

06--11

Maxi power fuses . . . . . . . . 2÷5

06--11

Fuel level . . . . . . . . . . . . . . . 7

06--11

Power fuses . . . . . . . . . . . . 5÷34

06--11

Indicator lights . . . . . . . . . . 8÷9

06--11

Battery cut--out . . . . . . . . . . 34

06--11

Sockets . . . . . . . . . . . . . . . . 35--36

06--11

Grid heater . . . . . . . . . . . . . 37

06--11

Electronic modules . . . . . . 37--38

06--11

Main Connectors . . . . . . . . 38--39

06--11

Ground points identification 40÷42

06--11

How to use the wiring diagrams . . . . . . . . . . . . . . . . . . 43÷47

06--11

Components in descriptive order . . . . . . . . . . . . . . . . . . 48÷52

06--11

List of tables for system without “standard and full optional” cab . . . . . . . . . . . . . . 53--54

06--11

Components with code in ascending order . . . . . . . . . 55÷57

06--11

Transmitters, sensors and switches . . . . . . . . . . . . . . . 10÷20

06--11

Electronic control unit inputs/outputs (ADIC) . . . . . . 21÷23

06--11

CHAPTER 2 -- Starting System Summary . . . . . . . . . . . . . . . 1

06--11

Technical data . . . . . . . . . . 2

06--11

Torque Specifications . . . . 2

06--11

Description and operation . 3

06--11

Starter and recharging circuit . . . . . . . . . . . . . . . . . . . . 4--5

06--11

Troubleshooting . . . . . . . . . 6--7

06--11

Fuse and relay locations . . 7--8

06--11

84419869A -- 06 -- 2011

CHAPTER 5 -- Electrical circuits

CONTENTS Page

Date

Tables . . . . . . . . . . . . . . . . . 58÷96

06--11

List of tables for system with “standard and full optional” cab . . . . . . . . . . . . . . 97--98

06--11

Components with code in ascending order . . . . . . . . . 99÷103

06--11

Tables . . . . . . . . . . . . . . . . . 104÷160

06--11

7 Page

Date

90 -- PLATFORM, CAB, BODYWORK CHAPTER 1 -- Cab Bonnet. Removal -- Installation . . . . . . . . . . . . . . . . . . . . 2

06--11

Cab assembly with platform. Removal -- Installation . . . . . . . . . . . . . . . . . . . . 3--4--5--6-7--8--9

06--11

Cab right--hand pillar guard removal -- installation . . . . . 10

06--11

Components in descriptive order . . . . . . . . . . . . . . . . . . 2÷7

06--11

Cab right--hand top guard removal -- installation . . . . . 11

06--11

Components with code in ascending order . . . . . . . . . 8÷12

06--11

Cab right--hand mudguard guard removal--installation 12

06--11

Harnesses . . . . . . . . . . . . . . 13÷20

06--11

Connectors . . . . . . . . . . . . . 21÷92

06--11

Cab left--hand top guard removal--installation . . . . . . . 13

06--11

Windows. Replace . . . . . . . 14--15--16

06--11

CHAPTER 6 -- Wiring Harnesses and Connectors Summary . . . . . . . . . . . . . . . 1

84419869A -- 06 -- 2011

CONTENTS

SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair work described in this manual must be performed exclusively by NEW HOLLAND service technicians, in strict accordance with the instructions given and using any specific tools necessary. Anyone performing the operations described herein without strictly following the instructions is personally responsible for any eventual injury or damage to property.

BATTERY Before carrying out any kind of service operation disconnect and isolate the battery negative lead, unless otherwise requested for specific operations (e.g.: operations requiring the engine to be running), after which it is necessary to disconnect the above--mentioned lead to complete the work.

SHIMMING For each adjustment operation, select adjusting shims and measure individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value indicated for each shim.

ROTATING SHAFT SEALS For correct rotating shaft seal installation, proceed as follows: -- before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes; -- thoroughly clean the shaft and check that the working surface on the shaft is not damaged; -- position the sealing lip facing the fluid; with hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will deviate the fluid towards the inner side of the seal; -- smear the sealing lip with a thin layer of lubricant (use oil rather than grease) and fill the gap between the sealing lip and the dust lip on double lip seals with grease; -- insert the seal in its seat and press down using a flat punch, do not tap the seal with a hammer or mallet; -- whilst inserting the seal, check that the it is perpendicular to the seat; once settled, make sure that it makes contact with the thrust element, if required; -- to prevent damaging the seal lip on the shaft, position a protective guard during installation operations.

O--RING SEALS Lubricate the O--RING seals before inserting them in the seats, this will prevent them from overturning and twisting, which would jeopardise sealing efficiency.

SEALING COMPOUNDS Apply one of the following sealing compounds on the mating surfaces marked with an X: LOCTITE 518 or LOCTITE 5205 or SUPERBOND 559 or BETALOK A272M. Before applying the sealing compound, prepare the surfaces as follows: -- remove any incrustations using a wire brush; -- thoroughly degrease the surfaces using one of the following cleaning agent: trichlorethylene, petrol or a water and soda solution.

BEARINGS When installing bearings it is advised to: -- heat the bearings to 80 รท 90 0C before fitting on the shafts; -- allow the bearings to cool before installing them from the outside.

84419869A - 06 - 2011

SECTION 00 -- GENERAL -- CHAPTER 1 SPRING PINS

When fitting split socket elastic pins, ensure that the pin notch is positioned in the direction of the force required to stress the pin. Spiral spring pins do not require special positioning

SPARE PARTS Use genuine parts only. Only genuine spare parts guarantee the same quality, duration and safety as they are the same parts that are assembled during production. Only genuine parts can offer this guarantee. When ordering spare parts, always provide the following information: -- tractor model (commercial name) and frame number; -- engine type and number; -- part number of the ordered part, which can be found on the ”Spare Parts Catalogue”, which is the base for order processing.

NOTES FOR EQUIPMENT The tools that NEW HOLLAND offer and illustrate in this manual are: -- specifically researched and designed for use with NEW HOLLAND vehicles; -- necessary to make a reliable repair; -- accurately built and strictly tested to offer efficient and long--lasting working means. By using these tools, repair personnel will benefit from: -- operating in optimal technical conditions; -- obtaining the best results; -- save time and effort; -- working in safe conditions.

IMPORTANT NOTES Wear limit values indicated for certain parts are recommended, but not binding. The terms ”front”, ”rear”, ”right--hand” and ”left--hand” (when referred to different parts) are intended as seen from the driving position with the tractor in the normal direction of movement.

MOVING THE TRACTOR WITH THE BATTERY REMOVED External power supply cables should only be connected to the respective positive and negative cable terminals, using efficient clamps that guarantee adequate and secure contact. Disconnect all services (lights, windshield wipers, etc.) before starting the vehicle. If the tractor electrical system requires checking, carry out operations with the power supply connected. Once checking is completed, disconnect all services and switch off the power supply before disconnecting the cables.

84419869A - 06 - 2011

SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY RULES PAY ATTENTION TO THIS SYMBOL This warning symbol points out important messages concerning your safety. Carefully read the following safety regulations and observe advised precautions in order to avoid potential hazards and safeguard your health and safety. In this manual the symbol is accompanied by the following key--words: WARNING -- Warnings concerning unsuitable repair operations that may jeopardise the safety of Repair personnel. DANGER -- Specific warnings concerning potential hazards for operator safety or for other persons directly or indirectly involved.

TO PREVENT ACCIDENTS Most accidents or injuries that occur in workshops are the result of non--observance of simple and fundamental safety regulations. For this reason, IN MOST CASES THESE ACCIDENTS CAN BE AVOIDED by foreseeing possible causes and consequently acting with the necessary caution and care. Accidents may occur with all types of vehicle, regardless of how well it was designed and built. A careful and judicious service technician is the best guarantee against accidents. Precise observance of the most basic safety rule is normally sufficient to avoid many serious accidents. DANGER. Never carry out any cleaning, lubrication or maintenance operations when the engine is running.

SAFETY RULES

---

GENERAL GUIDELINES ---

Carefully follow specified repair and maintenance procedures. Do not wear rings, wristwatches, jewels, unbuttoned or flapping clothing such as ties, torn clothes, scarves, open jackets or shirts with open zips which could get caught on moving parts. Use approved safety clothing such as anti--slipping footwear, gloves, safety goggles, helmets, etc.

1 Do not carry out repair operations with someone sitting in the driverâ&#x20AC;&#x2122;s seat, unless the person is a trained technician who is assisting with the operation in question. Do not operate the vehicle or use any of the implements from different positions, other than the driverâ&#x20AC;&#x2122;s seat. Do not carry out operations on the vehicle with the engine running, unless specifically indicated. Stop the engine and ensure that all pressure is relieved from hydraulic circuits before removing caps, covers, valves, etc. All repair and maintenance operations must be carried out using extreme care and attention. Service steps and platforms used in a workshop or in the field should be built in compliance with the safety rules in force. Disconnect the batteries and label all controls to indicate that the vehicle is being serviced. Block the machine and all equipment which should be raised. Do not check or fill fuel tanks, accumulator batteries, nor use starting liquid when smoking or near naked flames, as these fluids are inflammable. Brakes are inoperative when manually released for repair or maintenance purposes. Use blocks or similar devices to control the machine in these conditions. The fuel nozzle should always be in contact with the filling aperture: Maintain this contact until the fuel stops flowing into the tank to avoid possible sparks due to static electricity buildup.

84419869A - 06 - 2011

SECTION 00 -- GENERAL -- CHAPTER 1

4 --

-----

---

Only use specified towing points for towing the vehicle. Connect parts carefully. Make sure that all pins and/or locks are secured in position before applying traction. Never remain near the towing bars, cables or chains that are operating under load. Transport vehicles that cannot be driven using a trailer or a low--loading platform trolley, if available. When loading or unloading the vehicle from the trailer (or other means of transport), select a flat area capable of sustaining the trailer or truck wheels. Firmly secure the vehicle to the truck or trailer and lock the wheels in the position used by the carrier. Electric heaters, battery--chargers and similar equipment must only be powered by auxiliary power supplies with efficient ground insulation to avoid electrical shock hazards. Always use suitable hoisting or lifting devices when raising or moving heavy parts. Take extra care if bystanders are present. Never pour petrol or diesel oil into open, wide or low containers. Never use gasoline, diesel oil or other inflammable liquids as cleaning agents. Use non--inflammable, non--toxic commercially available solvents. Wear safety goggles with side guards when cleaning parts with compressed air. Limit the air pressure to a maximum of 2.1 bar, according to local regulations. Do not run the engine in confined spaces without suitable ventilation. Do not smoke, use naked flames, or cause sparks in the area when fuel filling or handling highly inflammable liquids. Never use naked flames for lighting when working on the machine or checking for leaks. All movements must be carried out carefully when working under, on or near the vehicle. Wear suitable safety clothing, i.e., hard hat, safety goggles and special shoes. When carrying out checks with the engine running, request the assistance of an operator in

84419869A - 06 - 2011

---

the driverâ&#x20AC;&#x2122;s seat. The operator must maintain visual contact with the service technician at all times. If operating outside the workshop, position the vehicle on a flat surface and lock in position. If working on a slope, lock the vehicle in position. Move to a flat area as soon as is safely possible. Damaged or bent chains or cables are unreliable. Do not use them for lifting or towing. Always use suitable protective gloves when handling chains or cables. Chains should always be safely secured. Make sure that the hitch--up point is capable of sustaining the load in question. Keep the area near the hitch--up point, chains or cables free of all bystanders. Maintenance and repair operations must be carried out in a CLEAN and DRY area. Eliminate any water or oil spillage immediately. Do not create piles of oil or grease--soaked rags as they represent a serious fire hazard. Always place them into a metal container. Before starting the tractor or its attachments, check, adjust and block the operatorâ&#x20AC;&#x2122;s seat. Also check that there are no persons within the vehicle or implement range of action. Empty pockets of all objects that may fall unobserved into the vehicle parts. In the presence of protruding metal parts, use protective goggles or goggles with side guards, helmets, special footwear and gloves. When welding, use protective safety devices: tinted safety goggles, helmets, special overalls, gloves and footwear. All persons present in the area where welding is taking place must wear tinted goggles. NEVER LOOK DIRECTLY AT THE WELDING ARC WITHOUT SUITABLE EYE PROTECTION. Metal cables tend to fray with repeated use. Always use suitable protective devices (gloves, goggles, etc.) when handling cables. Handle all parts with great care. Do not put your hands or fingers between moving parts. Always wear suitable safety clothing -- safety goggles, gloves and shoes.

SECTION 00 -- GENERAL -- CHAPTER 1 STARTING --

Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. Never place the head, body, limbs, feet, hands or fingers near fans or rotating belts.

ENGINE --

Always loosen the radiator cap slowly before removing it to allow any remaining pressure in the system to be discharged. Filling up with coolant should only be carried out with the engine stopped or idling (if hot). Never fill up with fuel when the engine is running, especially if hot, in order to prevent the outbreak of fire as a result of fuel spillage. Never check or adjust fan belt tension when the engine is running. Never adjust the fuel injection pump when the vehicle is moving. Never lubricate the vehicle when the engine is running.

ELECTRICAL SYSTEMS --

If it is necessary to use auxiliary batteries, remember that both ends of the cables must be connected as follows: (+) with (+) and (--) with (--). Avoid short--circuiting the terminals. GAS RELEASED FROM BATTERIES IS HIGHLY INFLAMMABLE. During charging, leave the battery compartment uncovered to improve ventilation. Never check the battery charge using â&#x20AC;?jumpersâ&#x20AC;? (metal objects placed on the terminals). Avoid sparks or flames near the battery zone. Do no smoke to prevent explosion hazards. Before servicing operations, check for fuel or current leaks. Eliminate any eventual leaks before proceeding with work. Never charge batteries in confined spaces. Make sure that there is adequate ventilation in order to prevent accidental explosion hazards as a result of the accumulation of gases released during charging operations. Always disconnect the batteries before performing any kind of servicing on the electrical system.

HYDRAULIC SYSTEMS --

enough to penetrate the skin. Therefore, use a piece of cardboard or wood for this purpose. NEVER DO IT WITH YOUR HANDS: If any liquid penetrates skin tissue, call for medical aid immediately. Failure to treat this condition with correct medical procedure may result in serious infection or dermatosis. In order to check the pressure in the system use suitable instruments.

WHEELS AND TYRES --

---

Make sure that the tyres are correctly inflated at the pressure specified by the manufacturer. Periodically check possible damages to the rims and tyres. Stand away from (at the side of) the tyre when checking inflation pressure. Only check pressure when the vehicle is unloaded and the tyres are cold, to avoid incorrect readings as a result of over--pressure. Do not reuse parts of recovered wheels as improper welding, brazing or heating may weaken the wheel and make it fail. Never cut or weld a rim mounted with an inflated tyre. To remove the wheels, lock both the front and rear vehicle wheels. After having raised the vehicle, position supports underneath, according to regulations in force. Deflate the tyre before removing any object caught in the tyre tread. Never inflate tyres using inflammable gases, as this may result in explosions and injury to bystanders.

REMOVAL AND RE--FITTING --

Lift and handle all heavy parts using suitable hoisting equipment. Make sure that parts are sustained by appropriate hooks and slings. Use the hoisting eyebolts for lifting operations. Extra care should be taken if persons are present near the load to be lifted. Handle all parts with carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear. Avoid twisting chains or metal cables. Always wear safety gloves when handling cables or chains.

A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful

84419869A - 06 - 2011

SECTION 00 -- GENERAL -- CHAPTER 1

TRACTOR REFUELLING

COMPONENT TO BE FILLED OR TOPPED UP

QUANTITY dm3 (litres)

Cooling system: less cab . . . . . . . . . . . . . . . . . .

14.0

with cab . . . . . . . . . . . . . . . . . .

RECOMMENDED NEW HOLLAND INTERNATIONAL NEW HOLLAND SPECIFICATIONS SPECIFICATIONS PRODUCTS

MS1710

16.0

Water & liquid AMBRA AGRIFLU 50% + 50%

Washer fluid reservoir . . . . . .

2.0

Water & liquid

Fuel tank . . . . . . . . . . . . . . . . .

Decanted, filtered diesel fuel

8.5

AMBRA Oil MASTERGOLD HSP

Brake control circuit . . . . . . .

0.7

AMBRA oil BRAKE LHM

ISO 7308

Front axle: axle housing . . . . . . . . . . . . . . final drives (each) . . . . . . . . .

4.5 1.0

AMBRA MULTI G oil

NH 410 B

API GL4 ISO 32/46 SAE 10W--30

AMBRA MULTI G oil

NH 410 B

API GL4 ISO 32/46 SAE 10W--30

Engine oil sump . . . . . . . . . . .

Rear transmission (bevel drive, final drives and brakes), gearbox, hydraulic lift, PTO and hydraulic steering: . . . . . -with mechanical transmissions . . . . . . . . . . . . . -- with hydraulic transmissions

NH 330H (SAE 15W--40) NH 324H (SAE 10W--40))

API CI--4/CH--4 ACEA E7/E5

30.0 35.0

Grease fittings . . . . . . . . . . . .

Grease AMBRA GR9

NH 710 A

NLGI 2

Air conditioner system -- refrigerant . . . . . . . . . . . . . . -- oil . . . . . . . . . . . . . . . . . . . . .

-1.3 0.185

R--134a SP10

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE

Chapter 1 -- Engine CONTENTS Section

Description

Page

10 000

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

10 001 10

Engine Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

10 216 10

Radiator -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Adjusting the accelerator control cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

NOTE: For the main data, tightening torques, tools, diagrams, lubrication and cooling diagrams, fault diagnosis, disassembly--assembly, checks and overhauling, see the Repairs Manual print no. 84242034A -- Italian; print no. 84208943A -- English; print no. 84242032A -- French; print no. 84242037A -- Spanish; print no. 84242033A -- German; print no. 84242031A -- Dutch; print no. 84242036A -- Portuguese; print no. 84242030A -- Danish.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

GENERAL SPECIFICATIONS Engine, technical type: --

mod. T4.55 -- type F5AE9454J*A (BOSCH pump) . . . . . . .

mod. T4.65 -- type F5AE9454L*A (BOSCH pump) . . . . . . .

mod. T4.75 -- type F5AE9454K*A (BOSCH pump) . . . . . . .

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

diesel, 4--stroke

Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Direct

Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99 mm

Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 mm

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3200 cm3

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

17.5 ± 0.5:1

Maximum Power Output: --

mod. T4.55 -- type F5AE9454J*A . . . . . . . . . . . . . . . . . . . . .

41 kW (55 Hp)

mod. T4.65 -- type F5AE9454L*A . . . . . . . . . . . . . . . . . . . . .

48 kW (65 Hp)

mod. T4.75 -- type F5AE9454K*A . . . . . . . . . . . . . . . . . . . . .

55 kW (75 Hp)

Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2300 rpm

Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1400 rpm

Torque Rise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35 (%)

Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

structural, cast iron

Lubrication

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

forced, with lobe pump

Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from crankshaft

Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via mesh filter on inlet and cartridge on delivery

Normal oil pressure with motor warmed--up at fast idling . . . . .

2.9 ÷ 3.9 bar

Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . .

coolant circulation 4 lines of vertical pipes with copper fins intake, in plastic with 11 blades

Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal vane--type

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via thermostat valve

initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79 ± 2 °C (continued)

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

3 (overleaf)

GENERAL SPECIFICATIONS Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . overhead valves operated by tappets, rods and rocker arms via the camshaft located in the engine block; the camshaft is driven by the crankshaft using straight--tooth gears Intake: --

start: before T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

19° ± 30’

end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37° ± 30’

Exhaust: --

start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

61° ± 30’

end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21° ± 30’

Clearance between valves and rocker arms with engine cold: --

intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.25 ± 0.05 mm

exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.50 ± 0.05 mm

Fuel system Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via dry air filter with double cartridge, clogging warning light with centrifuge prefilter and automatic exhaust of dust

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

with double diaphragm

Fuel filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via mesh filter in the fuel pump, a renewable cartridge filter on the delivery to the injection pump

Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

via engine timing

BOSCH Injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rotating distributor type

All--speed governor, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

centrifugal counterweights

Automatic advance regulator, incorporated in pump: BOSCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydraulic

Turbocharger --

type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

HOLSET rotating distributor with speed governor and advance variator incorporated

BOSCH pump: --

mod. T4.55 -- type F5AE9454J*A . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F1150--504246316

mod. T4.65 -- type F5AE9454L*A . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F1150--504246318

mod. T4.75 -- type F5AE9454K*A . . . . . . . . . . . . . . . . . . . . .

VE 4/12 F1150--504246318

Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

clockwise

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

1--3--4--2 (for all models)

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 001 10 ENGINE Removal--Installation

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. Carry out operation 90 150 10 -- Cab assembly with platform (do only the removal -- see sect. 90, chapter 1). 2. Extract the fixing pin and remove the ballast weights (1); unscrew the fixing screws and recover the ballast support (2).

1 3. Position a suitable container under the rear transmission, unscrew the plug (1) and drain off the oil from the transmission. NOTE: Consider that the prescribed quantity is: 35 litres for mechanical transmissions or 40 litres for hydraulic transmissions.

2 4. Disconnect the pipes (2 and 3) from the central auxiliary control valves, unscrew the bracket fixing screws (1) supporting the control valves and remove the unit.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

5. Disconnect the following pipes from the central auxiliary control valves: delivery (1) to the rear auxiliary control valves and return (2) to the transmission box.

4 6. Unscrew the relative retaining bolts and detach the cab right--hand support (1). Do this on both sides.

5 7. Disconnect and detach the pipes (1 and 2) connecting the power shuttle control valve to the cooler.

6 8. Disconnect the central auxiliary control valve connection line (5). 9. Disconnect the rear auxiliary control valve connection line (1). 10. Disconnect the four--wheel drive engagement control line (4). 11. Disconnect the PTO control line (2). 12. Disconnect the rear transmission lubrication line (3).

7 84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

13. Disconnect the intake pipe (1) from the rear transmission box and from the filter support, remove this pipe.

8 14. Unscrew the front, middle and rear fasteners, and detach the propeller shaft guard (1).

9 15. Remove the circlip (3) and move the sleeve (2) back to free it from the splined output shaft of the front axle (1), do this on the rear sleeve too.

10 16. Unscrew bolts (2) and remove the propeller shaft (1).

11 84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

17. Disconnect the pipes: (1) connecting to the hydraulic pump, (2) connecting to the central auxiliary control valves and (4) hydraulic pump inlet. 18. Unscrew the retaining bolts and remove the filter (3) and support.

12 19. Set a fixed stand under the clutch box, connect the rear of the engine to the hoist, unscrew the fixing screws (1) and detach the engine together with the front axle from the clutch box.

13 20. Disconnect the pipes (1) connecting to the transmission oil cooler.

14 21. Disconnect the radiator top sleeve (2). 22. Disconnect the sleeve (1) connecting the turbocharger to the air filter. 23. Unscrew the retaining bolts and detach the maxi--fuse support bracket (3).

15 84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

24. Disconnect the electrical connection (1) from the filter/dryer (2).

16 25. Unscrew the retaining bolts and detach the bracket (1) locking the radiator to the engine.

17 26. Disconnect the fittings (2) to separate the rigid pipes from the flexible hoses. 27. Detach the bracket (1) fixing the steering cylinder control lines.

18 28. Unscrew the bolt fastening the bracket (1) to the engine.

19 84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

29. Disconnect the pipes (1 and 2) from the cab air conditioning system compressor.

20 30. Set a fixed stand under the front of the front axle support and one under the back of it. 31. Connect the engine to a chain (1) and to the hoist.

21 32. Unscrew the bolts (1), on both sides, and remove the engine. 33. Then rest the engine on an adequate support. 34. To re--fit the engine, proceed as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

Using a chain connect the engine to the hoist and reattach it to the front axle support tightening the screws to the prescribed torque.

Connect the pipes to the compressor of the cab air conditioning system.

Using the appropriate bracket, secure the maxi--fuse connecting cable.

Secure the steering cylinder control lines using the relevant bracket.

Connect the steering cylinder control piping.

22 Position and secure the bracket retaining the radiator to the engine.

Connect the electrical connection to the filter/dryer.

Position and secure the maxi--fuse support bracket.

Position and secure the sleeve connecting the turbocharger to the air filter.

Position and secure the radiator upper sleeve.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

10 --

Position and connect the transmission oil cooler connecting pipes.

Connect the rear connection line.

Position the engine together with the front axle and secure it to the clutch box tightening the screws to the prescribed torque.

Connect the central auxiliary control valve connection line.

Position the oil filter, complete with support, and secure it to the engine.

Connect the pipes connecting the power shuttle control valve to the cooler.

Connect the pipes for the: hydraulic pump inlet, central auxiliary control valves connection and hydraulic pump connection.

Position and secure the right and left supports of the cab.

Connect the central auxiliary control valve connection line to the rear auxiliary control valves.

Connect the central auxiliary control valve return line to the rear transmission.

Position and secure the ballast support.

Position and secure the ballast.

Carry out operation 90 150 10 -- Cab with platform unit (perform installation only).

Screw the plug into the rear transmission box and fill with oil (see sect. 00, page 6 for prescribed product and quantity).

Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.

Position the propeller shaft guard and secure it.

Position the pipe drawing transmission and secure it.

Connect the rear transmission lubrication line.

Connect the PTO control line.

Connect the four--wheel drive engagement control line.

84419869A - 06 - 2011

oil

from

the

auxiliary

control valve

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 216 40 FUEL TANK Removal--Installation

23 2. Raise the rear of the tractor, position a fixed stand under the rear transmission box, unscrew the relevant fixing screws and detach the left rear wheel (1).

24 3. Unscrew the plug (1) and drain off the fuel from the main tank. Consider that the total capacity is 90 litres.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

4. Unscrew the relevant retaining bolts and remove the left steps (1). 5. Unscrew the two fuel tank fixing clamps (3). 6. Unscrew the screws fixing the bottom guard (2) and detach it.

26 7. Unscrew the clamps (1 and 3) and detach the fuel return and inlet lines. 8. Disconnect the electrical connection (2) of the fuel gauge.

27 9. Unscrew the two brackets (1 and 2) fixing the fuel return and inlet pipes, finally remove the fuel tank. 10. To refit the fuel tank, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --------

Position and secure the tank fuel return and fuel inlet lines. Secure the tank fuel return and fuel inlet lines using the appropriate brackets. Connect the electrical connection of the fuel gauge. Position the fuel tank and secure it with the clamps Position and secure the bottom guard of the fuel tank. Position and secure the left steps. Position and secure the left rear wheel.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

Op. 10 216 10 ENGINE COOLANT RADIATOR Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 100 22 -- Bonnet (perform removal only). 2. Carry out operation 50 200 72 -- Air--conditioning system condenser (perform removal only). 3. Carry out operation 21 109 40 -- Transmission oil cooler (perform removal only). 4. Loosen the clamp, detach the sleeve (1) from the radiator and drain off the coolant 5. Disconnect the air intake sleeve (1).

30 6. Disconnect the sleeve (1) from the air filter and from the turbocharger. 7. Disconnect the sleeve (2) from the radiator.

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

8. Disconnect: the pipes (1) and the electrical connection (2) from the filter/dryer.

32 9. Detach the engine coolant expansion tank (1).

33 10. Unscrew the top and bottom screws fixing the bracket (1) supporting the air filter and recover the unit together with the filter/dryer.

34 11. Disconnect the bracket (1) and disconnect the pipe (2) from the cab air conditioning system compressor.

35 84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

12. Unscrew the related bolts and remove the bracket (1) fixing the radiator to the engine. 13. On the right side, detach the brackets fixing the pipes of the air--conditioning system to the engine.

36 14. Detach the maxi--fuse support bracket (2) and unscrew the relevant screws to free the shroud (1) from the engine coolant radiator.

37 15. Unscrew the two bolts (1) and remove the engine coolant radiator. 16. Install the engine coolant radiator considering the following warnings.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---

---------

Position and secure the radiator on the front axle support. Secure: the shroud, maxi--fuse support bracket and the brackets fixing the air--conditioning pipes. Position and secure the radiator retaining bracket to the engine. Connect and secure the piping to the compressor. Position and secure the air filter unit and filter/dryer. Position the expansion tank. Connect: the pipes and the electrical connection to the filter/dryer. Connect the air filter sleeves. Connect the sleeves to the radiator. Connect the air intake sleeve.

-----

38 Carry out operation 21 109 40 Transmission oil cooler (perform installation only). Carry out operation 50 200 72 Air--conditioning system condenser (perform installation only). Carry out operation 90 100 22 -- Bonnet (perform installation only). Fill up the engine cooling system (see page 6, sect. 0 for prescribed product and quantity).

84419869A - 06 - 2011

SECTION 10 -- ENGINE -- CHAPTER 1

ADJUSTING THE THROTTLE CONTROL CABLE

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Connect the throttle control cable (2) to the injection pump and tighten the nut (1) to eliminate the play in the cable. 39 2. Fully tighten the throttle control pedal limit stop screw (1).

40 3. Apply a load (P) of 10 daN Â± 1 on the accelerator control pedal, tighten the limit stop screw (1) until contact is made with the platform and lock it by means of the relevant lock nut.

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

SECTION 18 -- CLUTCH Chapter 1 -- Clutch CONTENTS Section

Description

Page

18 000

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

18 110 10

Clutch -- Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

18 110 30

Dual disk clutch 11”/11” Test bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

18 100 40

Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

LUK 11”/11” CLUTCH -- GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

single disk, dry plate dual clutch unit

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

control: pedal operation for main clutch and hand lever for power take--off clutch

Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . .

single Belleville spring disc

Driven plate lining material for main transmission clutch: . . . . . . .

cerametallic

Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . .

organic

Driven disc thickness: --

main clutch (9, fig. 2): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10.2 ÷ 10.8

PTO clutch (11, fig. 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

”

7.4 ÷ 7.8

wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

”

see pages 10 and 11

Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . .

see page 11

Clutch control adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 12

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Clutch casing/engine retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque Nm

kgm

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

Screws (C1) fixing clutch box to the rear transmission box . . . . .

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

Screw (C2) securing levers to release command fork (7, fig. 1) .

M 16 x 1.5

136 ÷ 165

13.9 ÷ 16.9

11”/11” clutch/flywheel retaining bolts (C3) . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

20 ÷ 25

2 ÷ 2.5

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1 TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

List of specific tools required for the various operations described in this section. X 380001612

Pin for centering and adjustment of 11”/11” clutches.

X 380000293

Clutch adjustment gauge (with 380001612).

380000256

Set of wrenches for adjustment of levers in 11”/11” LUK clutches.

Longitudinal section of 11”/11” LUK clutch 1. PTO clutch release lever adjuster screw. 2. PTO clutch release levers. 3. Main clutch release levers. 4. Main clutch disk. 5. Main clutch release lever adjuster. 6. PTO clutch disk. 7. Belleville spring disk. D = 100.5 mm Nominal distance of the levers (8) from the clutch/engine flywheel mating surface. D1 = 140 mm. Nominal distance of the levers (4) from the clutch/engine flywheel mating surface.

NOTE: During installation, apply sealing compound to surfaces X as shown in Section 21, Chapter 1, page 22.

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

CLUTCH TROUBLESHOOTING Problems The clutch slips

Possible causes

Solutions

1. Worn disks 4 and 6, page 3, on Check and compare the data given on pressure plates and flywheel. the pages indicated, replace any parts which are worn up to or over the limit and adjust levers and clutch control linkage. 2. Belleville spring disk (7, page Replace the Belleville spring. 3) stretched or damaged. 3. Oil or grease contaminating Replace the disks, identify and elimithe friction lining of disks 4 and nate the source of the lubricant inside 6, page 3). the clutch housing and thoroughly clean the friction surfaces.

The clutch jerks

1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Clutch disk (4, page 3) defor- Replace the disk and adjust the clutch med. control lever. 3. Clutch disk (4, page 3) with Replace disk. torsion springs damaged or with hub rivets loose. 4. Oil or grease contaminating Replace the disks, identify and elimithe disks friction material (4 nate the source of the lubricant inside and 6, page 3). the clutch housing and thoroughly clean the friction surfaces.

Clutch sticks and drags

1. Clutch disks (4 and 6, page 3) Replace and adjust disks. deformed. 2. Seizure of external control lin- Check, replace faulty parts and lubrikage. cate. 3. Controls incorrectly adjusted. Adjust the controls (see page 12).

Clutch noisy when engaged and/or disengaged.

1. Thrust bearing worn.

Replace bearing

2. Clutch disk (4, page 3) with Replace disk. torsion springs faulty. Clutch pedal too stiff

1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Partial seizure of pedal pivot.

84419869A - 06 - 2011

Check pivot and lubricate.

SECTION 18 -- CLUTCH -- CHAPTER 1

Op. 18 110 10 CLUTCH Removal--Refitting

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Carry out operation 10 001 10 Engine, only removal (see sect. 10). 2. Using tool 380001612 (1), unscrew the retaining bolts and remove the clutch (2). 3. To install the clutch on the engine flywheel, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 2.

27785

3 --

Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (approximately 2 mm diameter), according to the diagram shown in Section 21, Chapter 1, on page 22.

Refit the clutch to the flywheel, using tool 380001612.

Carry out operation 10 001 10 Engine, only installation (see sect. 10).

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

Op. 18 110 30 11”/11” DUAL DISK CLUTCH -Test bench overhaul

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Unscrew the three PTO clutch lever adjustment nuts (1). 2. Recover the pressure plate (1) with the three coil springs (2) and the three washers.

24791

2 24792

5 3. Position three clamps (1) at intervals of 120° on the clutch body and gradually and carefully squeeze the Belleville spring disk.

24793

6 4. Extract the six spring retaining pins (1) from their seats.

24794

7 84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1 5. Remove the three clamps and extract the Belleville spring disk (1).

24975

8 6. Loosen the three locknuts (1) on the main clutch lever adjustment screws.

24976

9 7. Remove the three main clutch lever adjustment screws (1).

24977

10 8. Extract the main clutch pressure plate (1).

24978

11 84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

9. Extract the main clutch disk (1).

24979

12 10. Remove the springs (1) on the PTO clutch control levers.

24980

13 11. Extract the pivot pins (1) on the PTO clutch control levers.

24981

14 12. Remove the springs (1) on the main clutch control levers.

24982

15 84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1 13. Extract the pivot pins (1) on the main clutch control levers.

14. To refit the clutch, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Refit the lever pivot pins and the relative springs.

Refit the main clutch disk in the clutch housing.

Install the main clutch pressure plate, securing to the pins with the bolts.

Install the Belleville spring disk, carefully position the three clamps and evenly and progressively compress the spring. Insert the six pins, making sure that they are securely inserted in their respective seats, then remove the clamps.

Install the PTO clutch disk; fit the three washers and the coil springs on the pins and secure with the three nuts.

24983

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS DUAL DISK CLUTCH

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch A ≥ 15.5 mm; B ≥ 22.7 mm; D ≥ 15.8 mm. 1. Flywheel. 2. PTO clutch pressure plate. 3. Main clutch pressure plate. 4. Clutch cover.

Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch. --

Check the friction surface conditions of the pressure plates and the clutch casing. Generally, by means of turning, up to 1 mm of material can be removed from the cast iron friction surfaces of the clutch cover (3), the pressure plate ring (2) and the flywheel (see engine repair manual). When parts (1), (2), (3) and (4, fig. 17), are to be repaired by removing material, proceed as follows: -- If it is necessary to reface the friction surfaces on the PTO clutch pressure plate (2, fig. 17), remember that the amount removed in relation to the nominal thickness (A), must also be removed from the base of the flywheel housing (4, fig. 17) in order to regain the original position of the pressure plate (2) in relation to the flywheel. The position indicated by (C) of the clutch cover (4, see fig. 17) must be calculated using the following formula: C = 71.4 + A Where: A = Thickness of the pressure plate after refacing. C = Height of the clutch cover after refacing.

84419869A - 06 - 2011

25966

SECTION 18 -- CLUTCH -- CHAPTER 1 --

When the friction surfaces of the main clutch pressure plate ring (3, fig. 17) or the clutch cover (4), need refacing, remember that the removal of material cannot be compensated by turning the clutch cover (4) on the flywheel side. Therefore the least possible material should be removed from parts (3 and 4), for longer clutch life.

NOTE: If, after having refaced parts (3 and 4, fig. 17) several times, the main clutch disk starts to slip, the entire clutch assembly must be replaced. --

Refit the clutch assembly as shown on page 6.

COPLANARITY ADJUSTMENT OF 11â&#x20AC;?/11â&#x20AC;? DUAL CLUTCH RELEASE 1. After overhauling the clutch, fit the centering pin 380001612 (1) and fit the entire clutch assembly to the flywheel, then tighten the bolts (2).

25968

18 2. Fit gauge 380000293 (1) on the centering pin and, using a feeler gauge, adjust the main clutch release levers (2) to obtain a clearance of 0.1 mm.

25969

19 3. Rotate the gauge 380000293 (1) and, with the aid of a feeler gauge, adjust the PTO clutch release levers (2) to obtain a clearance of 0.1 mm.

25970

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

Op. 18 100 40 MAIN CLUTCH ADJUSTMENTS

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. If the position of the clutch pedal (1) requires adjustment, or after a clutch overhaul, check that the main clutch pedal height (A) is: A = 143 รท 147 mm (for tractors with cab); A = 153 รท 157 mm (for tractors with ROPS and noise deadening mat; A = 158 รท 162 mm (for tractors with ROPS). If not adjust as follows: 21 ----

Unlock the lock nut (1) and turn the screw (2). Check that the pedal height is as specified. Tighten the locknut (1).

25974

22 ---

Operate the unit four or five times. Check that the clutch pedal (1) height is as prescribed.

25975

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

PTO CLUTCH SERVO CONTROL

24 Cross--section of PTO servo control 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Discharge oil pipe. Oil delivery pipe to control piston. Pressurized oil pipe, from pump. Dust ring. O -- Ring seal. Control valve drive pin. PTO clutch lever. Locknut. Flexible protective sleeve. Piston body.

11. 12. 13. 14. 15. 16. 17. 18. 19.

Seals. Control piston. Safety ring. Control valve lever, connected by cable to control lever in cab. Lever control linkage (7). Safety ring. O -- Ring seal. Spring. Control valve body.

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

3 4 5

2 8 3 7 1 6

MDE0552A

Pressurised oil

Discharge oil 25

DESCRIPTION AND OPERATION ENGAGING THE PTO CONTROL CLUTCH The PTO clutch control system consists of a control lever (in the cab) and a cable connecting the lever to the servo control unit. The servo control unit consists of a hydraulic control valve and piston. When the PTO clutch is engaged with the control lever in the cab, the connecting cable acts on the lever (8) which, as it moves, pushes up the control valve drive pin (4).

84419869A - 06 - 2011

When the pin (4) moves up it closes the hole leading to the oil discharge pipe (1). The oil from the pump passes through line (3), line (2), and acts on the piston (6). The piston (6), under an oil pressure of 15.7 (16) bar (kg/cm2) moves and, by means of tie--rod (7), moves lever (5), engaging the PTO clutch.

SECTION 18 -- CLUTCH -- CHAPTER 1

2 1 3 4 5

MDE0553A

Pressurised oil

Discharge oil

DISENGAGING THE PTO CONTROL CLUTCH When the PTO clutch is disengaged with the lever in the cab, the linkage releases the clutch control lever (5).

26 In this position, the pipe (2) that delivers the oil to the piston (6) communicates with the discharge pipe (1) so that the oil can flow away from the piston. When the piston (6) lowers it moves lever (5) with the linkage (7) and disengages the PTO clutch.

The spring (9) moves the control valve drive pin (4) down to stop the oil pumped in through pipe 3 from going into pipe (2).

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

ADJUSTING THE PTO CLUTCH SERVO CONTROL

ATTENTION

2. Push the clutch lever (1) up.

3. Connect the fork (2) to the lever (1) by unscrewing the lever so that the control piston (5) goes against the bottom of the cylinder (6).

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

4. Unscrew the fork (2) one turn (1.25 mm) so that there is an internal clearance between the clutch control sleeve and levers.

1. Detach the protective sleeve (4) from the fork pin (2) and unscrew the locknut (3).

5. Tighten the locknut (3) and attach the protective sleeve (4) to the fork pin (2).

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

ADJUSTING THE PTO SWITCH

ATTENTION

28 2. Unscrew the screws (1) retaining the PTO engaged switch (2) and move away from the control valve lever (3).

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

3. Move the switch (2) towards the control valve lever (3 )until the switch trips.

1. Check that the PTO clutch is disengaged.

4. Lock the switch (2) in this last position with the screws (1).

84419869A - 06 - 2011

SECTION 18 -- CLUTCH -- CHAPTER 1

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

SECTION 21 -- GEAR TRANSMISSION Chapter 1 -- Mechanical transmission CONTENTS Section

Description

Page

21 000

21 118 10

Rear transmission casing--gearbox Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10

21 118 12

Rear transmission casing--gearbox Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 10

21 118 85

Gearbox transmission casing Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

21 140 85

Clutch housing -- Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

21 140 87

Clutch housing -- Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

21 109 40

Transmission oil cooler. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical type with spur gearing, located between the main clutch and the gearbox.

Control with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hand lever located on left--hand side of steering wheel

CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the shuttle. Providing 20 forward gears and 20 reverse gears

Control with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hand lever located on left--hand side of the operator (continued)

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

TRANSMISSION AND RANGE GEAR MAIN DATA (overleaf)

Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--speed constant mesh, synchronised on all gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

helical gears

Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ordinary gear train with 3 ranges for a total of 12 gears

gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spur

Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .

independent, by means of lever located on right--hand side of operator

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Retaining bolts securing creeper clutch casing to rear transmission/gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque Nm

kgm

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

Bolts securing creeper clutch casing to the engine . . . . . . . . . . . .

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

Bearing support retaining bolts (C1) . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

84 ÷ 93

8.6 ÷ 9.5

Gearbox driving and driven shafts bearing cover screws (C2) . . .

M 8 x 1.25

20 ÷ 25

2.0 ÷ 2.5

Gearbox and range control relay levers support cover retaining screws (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

43 ÷ 51

4.4 ÷ 5.2

Parking brake support retaining bolts (North American version) (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

60 ÷ 75

6.1 ÷ 7.6

Drive gear housing retaining bolts (C5) . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

43 ÷ 51

4.4 ÷ 5.2

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

TORQUE SPECIFICATIONS

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

84419869A - 06 - 2011

List of specific tools required for the various operations described in this section. 380000227

Clutch casing lift hook.

380000301

Turning stand for overhaul.

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Longitudinal section of the reverser and creeper A. Version with reverser. 6. Reverse gear drive shaft. 7. Creeper fork. B. Version with reverser and creeper unit. 8. Rod for fork (7). 1. Driving shaft. 9. Poppet spring and ball. 2. Shuttle selector synchroniser. 10. Reverser synchronizer control fork. 3. Forward gear drive shaft. 11. Rod for fork (10). 4. Creeper unit driven gear. 12. Poppet spring and pawl. 5. Reverse gear and creeper unit drive shaft.

NOTE: When mounting apply sealing compound to surfaces X as shown on pages 22. 84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

3 Longitudinal cutaway section through gearbox and range gear. 1. 2. 3. 4. 5. 6. 7.

1st speed gear. Transmission input shaft. 2nd speed gear. Power Take--Off drive shaft. 3rd speed gear. 3rd and 4th gear engagement synchronizer. 4th speed gear.

8. 9. 10. 11. 12. 13.

Selector sleeve for low speeds. Low speed drive gear. Medium speed drive gear. Medium and fast speed drive gear. Transmission output shaft. 1st and 2nd gear engagement synchronizer.

NOTE: When mounting apply sealing compound to surfaces X as shown on pages 22.

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

4 Cross--sectional view of gearbox and range gear A. 1. 2. 3. 4.

Detail of 8--gear transmission version. Medium and fast speed drive gear. Drive gear. Transmission and gearbox lubrication oil sleeve. Services control pressure adjustment valve.

5. 6. 7. 8.

Transmission poppet balls and springs. Speed control safety pawl. Range gear poppet balls and springs. Range gear control safety pawl.

DESCRIPTION AND OPERATION 84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Gearbox and shuttle 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers The range gear has cascade--type constant--mesh spur gears. The range gears can provide 3 ranges of gears (12--gear version) or 2 ranges (8--gear version). The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The shuttle is a mechanical device making it possible to obtain 12 forward gears and 12 reverse gears or 8 forward gears and 8 reverse gears. It is controlled by a lever located to the left of the steering wheel. The reverser is composed of a group of three spur gears: driving reverser gear, intermediate gear and driven reverser gear. Selection is effected by means of a synchronizer located in the gear unit.

The reverser is installed inside the clutch casing, between the clutch and the gearbox. Lubrication is by means of the oil in the rear transmission/gearbox. Creeper unit The creeper unit is a mechanical device that can provide 20 forward gears and 20 reverse gears (12--gear version) or 12 forward gears and 12 reverse gears (8--gear version). The creeper unit only intervenes in slow and medium--slow ranges, a mechanical interlock prevents creeper engagement in the fast range. The creeper unit is composed of a group of three spur gears: a sliding control gear, a driving gear shaft and a driven gear. The creeper unit is installed upstream from the reverser and is controlled by the specific lever located on the right--hand side of the operator.

GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING

Problems

Possible causes

Solutions

Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. incorrectly adjusted. gearbox, creeper or shuttle. 2. Control lever retaining springs Renew the springs. damaged. 3. Synchronisers or selection Remove the transmission / gearbox sleeves damaged. and replace the synchronisers or engagement sleeves. 4. Engagement travel incom- Eliminate the cause and restore full plete. engagement travel. (continued)

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING (overleaf)

Problems

Possible causes

Solutions

Difficulty in engaging the gearbox, 1. External levers and relay rods Adjust correctly. incorrectly adjusted. creeper or reverser units. 2. Stiffness and/or partial Check rod pivots and lubricate. seizure of external levers and relay rods. 3. Main clutch dragging.

See sect. 18.

4. Synchronisers or selection Remove the transmission / gearbox sleeves damaged. and replace the synchronisers or engagement sleeves. 5. Internal controls do not slide Overhaul the controls. freely: rods, forks and sleeves. Excessive noise in creeper or reverser.

gearbox, 1. Worn or damaged internal Remove the transmission--gearbox parts. casing and replace the damaged parts.

CREEPER UNIT TROUBLESHOOTING Problems

Possible causes

Solutions

Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. creeper unit incorrectly adjusted. 2. Engagement travel incom- Eliminate the cause and restore full plete. engagement travel. Difficulty in engaging the creeper 1. External levers and relay rods Adjust correctly. unit incorrectly adjusted. 2. Stiffness and/or seizure of ex- Check rod pivots and lubricate. ternal levers and rods 3. Main clutch dragging.

See sect. 18.

4. Selector sleeve damaged.

Remove the clutch--gearbox casing and replace the sleeve.

5. Internal controls do not slide Overhaul the controls. freely: rods, forks and sleeves. Excessive noise in creeper.

1. Worn or damaged internal Remove the clutch casing and parts. replace the damaged parts.

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Op. 21 118 10 -- 21 118 12 REAR TRANSMISSION--GEARBOX CASING Removal--Installation

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Carry out operation 90 150 10 Cab with platform unit, only removal (see Sect. 90, Chapter 1). 2. Extract the fixing pin and remove the ballast weights (1); unscrew the fixing screws and recover the ballast support (2).

5 3. Position a suitable container under the rear transmission, unscrew the plug (1) and drain off the oil from the transmission. NOTE: Consider that the prescribed quantity is: 35 litres for mechanical transmissions or 40 litres for hydraulic transmissions.

6 4. Disconnect the pipes (2 and 3) from the central auxiliary control valves, unscrew the bracket fixing screws (1) supporting the control valves and remove the unit.

84419869A - 06 - 2011

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

5. Disconnect the following pipes from the central auxiliary control valves: delivery (1) to the rear auxiliary control valves and return (2) to the transmission box.

8 6. Unscrew the relative retaining bolts and detach the cab right--hand support (1). Do this on both sides.

9 7. Disconnect and detach the pipes (1 and 2) connecting the power shuttle control valve to the cooler.

10 8. Disconnect the intake pipe (1) from the rear transmission box and from the filter support, remove this pipe.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

9. Disconnect the central auxiliary control valve connection line (5). 10. Disconnect the rear auxiliary control valve connection line (1). 11. Disconnect the four--wheel drive engagement control line (4). 12. Disconnect the PTO control line (2). 13. Disconnect the rear transmission lubrication line (3).

12 14. Unscrew the front, middle and rear screws, and detach the propeller shaft guard (1).

13 15. Remove the circlip (3) and move the sleeve (2) back to free it from the splined output shaft of the front axle (1), do this on the rear sleeve too.

14 16. Unscrew bolts (2) and remove the propeller shaft (1).

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

16 19. Set a fixed stand under the clutch box, connect the rear of the engine to the hoist, unscrew the fixing screws (1) and detach the engine together with the front axle from the clutch box.

17 20. Disconnect the electric connection (1 and 3) and detach the PTO drive rod (2) from the control valve.

18 21. Place a stand under the front portion of the rear transmission casing. Connect the clutch casing (1) to the hoist using chains or nylon ropes, unscrew the screws fixing to the rear transmission box and detach the clutch casing.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

22. Detach the bottom lift arm (3) with the vertical tie--rod (1) and anti--shake brace (2). Do this on both sides.

20 23. Extract the relevant retaining pins and remove the external range gear control levers (1).

21 24. Using a nylon rope (2) or a chain, connect the final drive box (1) to the hoist, unscrew the relevant screws fastening to the rear transmission box and detach the box (1). Do this on both sides.

22 25. Detach the delivery pipe (1) from the rear auxiliary control valves to the lift control valve.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

26. Unscrew the four retaining bolts and detach the rear auxiliary control valve assembly (1) from the lift body.

24 27. Using a chain, connect the hydraulic lift body (1) to the hoist, unscrew the relevant fixing screws and detach the above part from the rear transmission box.

25 28. Detach the tank (1) from the rear transmission box.

26 29. Using a chain, connect the PTO box to the hoist, unscrew the relevant screws fixing to the rear transmission box and detach the above part. 30. To refit the rear transmission--gearbox casing, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

16 ---

-------

---

------

For the correct orientation of the various parts, refer to the illustrations on pages 5, 6 and 7. Before refitting the housings, supports and covers clean and de--grease the mating surfaces and apply sealing compound in a bead of approx. 2 mm in diameter as shown in the figure on page 22. Respect the tightening torque values prescribed on page 2. Position and secure the PTO box to the rear transmission box. Position the tank on the rear transmission housing. Position and secure the hydraulic lift to the rear transmission box. Position and secure the rear auxiliary control valve assembly to the hydraulic lift. Position and secure the delivery pipe from the rear auxiliary control valves to the hydraulic lift control valve. Position and secure the final drive casing to the rear transmission box. Do this on both sides. Position and secure the external levers governing the range gear to the relevant pins. Connect the bottom lift arm, vertical tie--rod and anti--shake brace. Do this on both sides. Position and secure the clutch casing. Connect the power take off control rod and the electric connections. Position the engine together with the front axle and secure it to the clutch casing. Position the oil filter, complete with support, and secure it to the engine. Connect the pipes for the: hydraulic pump inlet, central auxiliary control valves connection and hydraulic pump connection.

84419869A - 06 - 2011

Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.

Position the propeller shaft guard and secure it.

Connect the rear transmission lubrication line.

Connect the PTO control line.

Connect the four--wheel drive engagement control line.

Connect the rear connection line.

Connect the central auxiliary control valve connection line.

Position the pipe drawing transmission and secure it.

Connect the pipes connecting the power shuttle control valve to the cooler.

Position and secure the right and left supports of the cab.

Connect the central auxiliary control valve connection line to the rear auxiliary control valves.

Connect the central auxiliary control valve return line to the rear transmission.

Position and secure the ballast support.

Position and secure the ballast.

Carry out operation 90 150 10 -- Cab with platform unit (perform installation only).

Screw the plug into the rear transmission box and fill with oil (see sect. 00, page 6 for prescribed product and quantity).

auxiliary

control valve

oil

from

the

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Op. 21 118 85 GEARBOX TRANSMISSION CASING Disassembly--Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the rear transmission box detached from the clutch casing (see Op. 21 118 10 -- 21 118 12). Proceed as follows. 1. Position the rear transmission box on an adequate support. 2. Detach the parking brake lever (2). 3. Unscrew the relevant fixing screws and remove the cover (1) supporting the control levers: gearbox, range gear and parking brake 28 4. Unscrew the retaining bolts and detach the drive housing (1).

29 5. Extract the PTO shaft (2) together with the sliding sleeve (1).

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

6. Remove the circlips (1 and 2). 7. Unscrew the retaining bolts and remove the bearing guard (4). 8. Remove the circlips from the bearings. 9. Unscrew the relative retaining bolts and detach the support (1).

31 10. Unscrew the gearbox lubrication fitting (1), take out the screw (2) and the relevant plate. 11. Extract the internal lubrication sleeve.

32 12. Remove the circlips (1 and 2) and extract the transmission input and output shafts together with the relevant gears. 13. To re--fit the transmission--gearbox casing, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

For the correct orientation of the various parts, refer to the illustrations on pages 5, 6 and 7.

Respect the tightening torque values prescribed on page 2.

33 Position and secure the bearing guard, insert the external circlips.

Insert the transmission input and output shafts together with the gears and bearings into the rear transmission box, secure everything by means of the relevant circlips.

Insert the PTO shaft together with sliding sleeve.

Position and secure the drive box.

Position and secure the cover of the control levers for the gearbox, range gear and parking brake.

Insert the internal lubrication sleeve, secure the plate and screw on the external fitting.

Position and secure the front support, insert the internal circlips.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Op. 21 140 85 -- 21 140 87 CLUTCH CASING Disassembly--Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 21 118 12 -- Rear transmission--gearbox casing (perform removal only). 2. turn the thrust--bearing assembly (1) through 90_ and extract it. 3. Unhook the springs (1), unscrew the fixing screws, extract the relevant rods and recover the forks (2).

35 4. Unscrew the relative retaining bolts and detach the sleeve (1).

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

5. Unscrew the sensor (1).

37 6. Extract the drive gear assembly (2) together with the fork (1) and rod (3), recover the poppet spring and ball.

38 7. Remove the driven shaft (1) from the clutch housing.

39 8. Unscrew the reverse speed idle gear fixing screw (1).

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

9. Extract the reverse speed idle gear (1) together with the relevant pin.

41 10. Remove the circlip (1) and withdraw the drive shaft (2) complete with bearing. 11. To refit the clutch casing, proceed as follows

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Insert the drive shaft and secure it by means of the circlip.

Position and secure the reverse speed idle gear.

Position the driven shaft on the clutch housing.

Insert the drive gear assembly together with the poppet ball and spring, fork and relevant rod.

Screw on the sensor.

Position and secure the sleeve.

Position and secure the clutch forks, hook on the relative springs.

Insert the thrust--bearing assembly.

Carry out operation transmission--gearbox installation only).

21 118 casing,

12 Rear (perform

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

27152

43 Sealing compound application diagram for transmission--gear box casing The types of sealing compounds to be applied are specified on page 1, Sect. 00.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

Op. 21 109 40 TRANSMISSION OIL COOLER Removal -Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Raise the bonnet. 2. Raise the front part of the tractor, set a fixed stand under the engine sump and take off the left wheel. 3. Disconnect the pipes (1), unhook the relevant catch and extract the cooler (2).

4. Refit the transmission oil cooler considering the following warnings.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Insert the cooler, secure it and connect the pipes.

Position and secure the left front wheel.

Close the bonnet.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 1

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

SECTION 21 -- GEAR TRANSMISSION Chapter 3 -- Power Shuttle Transmission CONTENTS Section

Description

Page

21 000

21 110 87

Clutch casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

21 110 88

Clutch casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

21 118 85

Gearbox transmission casing Disassembly -- Assembly . . . . . . . . . . . . . . . . . . see chapter 1

REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical with spur gearing, located in front of the clutch assembly.

Control with . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hand lever located on left--hand side of steering wheel

CREEPER UNIT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the shuttle. It allows 20 forward gears and 20 reverse gears (12--gear version) or 12 forward gears and 12 reverse gears (8--gear version)

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

with lever located on right--hand side of operator

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

TRANSMISSION AND RANGE GEAR MAIN DATA Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--speed constant mesh, synchronised on all gears

Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

helical gears

Reduction unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ordinary gear train with 2 or 3 ranges for a total of 8 or 12 gears.

gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

spur

Gearbox and reduction unit controls . . . . . . . . . . . . . . . . . . . . . . . . .

independent, by means of lever located on right--hand side of operator

For missing data see Chapter 1, page 2. POWER SHUTTLE MAIN DATA Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .

no.

Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.95 ÷ 2.05 (1)

Drive disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.15 ÷ 2.25 (1)

Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

sintered

Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .

no.

Driven disc thickness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.95 ÷ 2.05

Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (163.1 kg)

steel mm

Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Shuttle and services transmission working pressure (kg/cm@) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.3 ÷ 16.5 (1) mounted on the outer left--hand side of the clutch casing.

bar

15.7 (16)

Accumulator spring (3, page 11): --

spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

122

spring length under load of 325 ÷ 359 N (33.2 ÷ 36.6 kg) . . .

100

Accumulator spring (6, page 11): --

spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84.5

spring length under load of 357 ÷ 387 N (36.5 ÷ 39.5 kg) . . .

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

paper cartridge

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

fixed to the pump body on suction side

Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the same as used for the hydrostatic steering system

(1) Value to obtain by varying the thickness of the driving plates

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Tightening torque Nm

kgm

30 ÷ 34

0.17 ÷ 0.28

For missing data see Chapter 1, page 2. Torsion coupling fixing screws (C1) (•) . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

Clutch manifold fixing screws (C2) . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

20.5÷ 25.5 1.52 ÷ 2.07

Retaining bolts securing clutch casing to rear transmission box (C3)

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

Clutch casing/engine retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

117 ÷ 129

11.9 ÷ 13.1

(•) Apply LOCTITE 270 before screwing on

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

84419869A - 06 - 2011

List of specific tools required for the various operations described in this section. 380000227

Clutch casing lift hook.

380000301

Turning stand for overhaul.

X 380000240

Hydraulic pressure testing kit.

X 380000278

Hydraulic pressure testing kit.

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

2 Longitudinal cross--sectional view of Power Shuttle and creeper unit gearbox 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Torsion damper disc. Clutch control shaft. Front manifold. Reverse drive gear. Drive discs. Driven clutch plates. Reverse drive clutch. Reverse drive clutch casing and power take--off. PTO clutch. Forward drive clutch casing.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20.

Forward drive clutch. Forward gear drive shaft. Creeper unit driven gear. Power Take--Off drive shaft. Reverse gear and creeper unit drive shaft. Creeper unit gear. Rear manifold. Forward drive clutch piston. Reverse drive clutch piston and power take--off. Reverse driven gear.

NOTE: When mounting apply sealing compound to surfaces X as shown on page 22, chap.1.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

3 Longitudinal cross--sectional view of Power Shuttle gearbox. 1. 2. 3. 4. 5. 6. 7. 8.

Front manifold. Reverse drive gear. Drive discs. Driven clutch plates. Reverse drive clutch. Reverse drive clutch casing and power take--off. PTO clutch. Forward drive clutch casing.

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9. 10. 11. 12. 13. 14. 15. 16.

Forward drive clutch. Forward gear drive shaft. Reverse gear drive shaft. Rear manifold. Forward drive clutch piston. Power Take--Off drive shaft. Reverse drive clutch piston and power take--off. Reverse driven gear.

SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

4 Cross--sectional views of Power Shuttle and creeper unit gearbox. 1. 2. 3. 4. 5. 6.

Creeper unit control rod. Poppet spring and ball. Creeper fork. Reverse intermediate gear. Reverse driven gear. Accumulator cover.

7. 8. 9. 10. 11.

Accumulator main spring. Rear manifold sleeve. Rear manifold sleeve. Accumulator secondary spring. Accumulator piston.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

DESCRIPTION AND OPERATION Gearbox and shuttle 4--speed gearbox with constant--mesh helical gears controlled by two synchronizers The range gear has cascade--type constant--mesh spur gears. The range gears can provide 3 ranges of gears (12--gear version) or 2 ranges (8--gear version). The gearbox and the range gears are controlled by two independent levers located on the right--hand side of the operator. The reverser is a mechanical device making it possible to obtain 12 forward gears and 12 reverse gears (12 gear version) or 8 forward gears and 8 reverse gears (8 gears version). It is controlled by a lever located on the control panel to the left of the steering wheel. Speed reversal is obtained by means of the lever located on the left--hand side of the steering wheel. It is not necessary to press the clutch pedal, but the engine rpm and tractor speed must be reduced. The reverser is composed of a group of three spur gears: driving reverser gear, intermediate gear and driven reverser gear. Selection is effected by means of a synchronizer located in the gear unit. The reverser is fitted inside the clutch casing in front of the clutch assembly. Lubrication is by means of the oil in the rear transmission/gearbox.

Creeper unit The creeper unit is a mechanical device allowing reduced speeds to be obtained. The creeper unit only intervenes in slow and medium ranges, a mechanical interlock prevents creeper engagement in the fast range. The creeper unit is composed of a group of three spur gears: a sliding control gear, a driving gear shaft and a driven gear. The creeper unit is installed upstream from the reverser and is controlled by the specific lever located on the right--hand side of the operator. Power Shuttle unit The Power Shuttle gearbox is controlled by two multi--disk clutches in an oil bath. This provides hydraulic control of 4 gears for each range, both forward and in reverse Gear and range selection is performed by pressing the clutch pedal and operating the control levers located on the right--hand side of the operator. The front clutch governs the reverse gears, the rear clutch governs the forward gears, the central clutch governs the power take off. The Power Shuttle gearbox allows 20 forward gears and 20 reverse gears (12--gear version) or 12 forward gears and 12 reverse gears (8--gear version)

GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING See Chapter 1, pages 8 and 9.

GEARBOX, CREEPER UNIT AND SHUTTLE TROUBLESHOOTING See Chapter 1, page 9.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

Op. 21 110 88 -- 21 110 87 CLUTCH CASING Disassembly--Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 21 118 12 -- Rear transmission--gearbox casing (perform removal only). 2. Unscrew the relevant fixing screws and detach the control valve (1) governing the power shuttle, recover the poppet spring.

3. Extract the drive gear assembly (2) together with the fork (1) and rod (3), recover the poppet spring and ball.

6 4. Unscrew the relative retaining bolts and detach the accumulator cover (1).

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

5. Remove the circlip (2), unscrew the relevant screws and detach the cover (1) together with the reverse speed idle gear. 6. Extract: the reverse gear from the driven shaft and the drive shaft together with the reverse and power take off clutches.

8 7. Unscrew the screws (1) fixing the inside manifold of the power shuttle.

9 8. Detach the internal pipes (1 and 2) from the manifold and extract the forward drive clutch assembly.

10 9. Remove the circlip (1) from the driven shaft.

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

10. Remove the driven shaft (1) from the clutch housing. 11. To refit the clutch casing, proceed as follows

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

For the correct orientation of the various parts, refer to the illustrations on pages 5, 6 and 7.

Respect the tightening torque values prescribed on page 2.

Position the driven shaft on the clutch casing and secure it using the relevant circlip.

Insert the forward drive clutch assembly, insert the internal pipes of the manifold and secure the manifold using the relevant screws.

Insert the power take--off and reverse clutch assembly.

Insert the reverse gear on the driven shaft.

Position and secure the cover together with the reverse drive idle gear, insert the relevant circlip.

Position and secure the accumulator cover.

Position the driven shaft on the clutch housing.

Position and secure the power shuttle control valve together with the poppet spring.

Carry out operation transmission--gearbox installation only).

21 118 casing,

12 Rear (perform

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SECTION 21 -- GEAR TRANSMISSION -- CHAPTER 3

MAIN CLUTCH ADJUSTMENTS

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Press the clutch control pedal (1) fully down.

13 2. Unscrew the lock nut (1) of the fork (2). 3. Adjust the length of the cable until the fork (2) can be connected to the power shuttle control valve lever (3). 4. Release the clutch pedal. 5. Tighten the lock nut (1) taking care not to change the position taken in point 3.

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

SECTION 23 -- DRIVE LINES Chapter 1 -- Drive lines CONTENTS Section

Description

Page

23 000

23 101 26

Propeller shafts and guard. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

23 101 40

Drive gear assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

23 202 50

Drive gear assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

MAIN SPECIFICATIONS -- 4WD ELECTROHYDRAULIC ENGAGEMENT Internal diameter of sliding sleeve (16, fig. 2) . . . . . . . . . . . . . . . . .

35.080 ÷ 35.119

Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35.002 ÷ 35.027

Internal diameter of sliding sleeve (16) . . . . . . . . . . . . . . . . . . . . . .

50.080 ÷ 50.119

Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.975 ÷ 50.000

Length of spring (20, with spring free) . . . . . . . . . . . . . . . . . . . . . . .

Length of spring (20) under a load of 93.2 ÷ 101.2 kg . . . . . . . . . .

MAIN DATA OF PROPELLER SHAFT Thickness of rings (2, fig. 3) that adjust the position of the front sleeve (3) of the four--wheel drive propeller shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.5 -- 1.9 -- 2.2 -- 2.5 -- 2.8 -- 3 -3.3 -- 3.7 -- 4 -- 4.3

Front sleeve end float (L) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.0 ÷ 1.5

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SECTION 23 -- DRIVE LINES -- CHAPTER 1 TORQUE SPECIFICATIONS

C--88Nm

27836

1 PARTS TO BE TIGHTENED

Thread

Tightening torque Nm

kgm

8.9

Drive gear housing retaining bolts (C1) . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

41 รท 51

4.2 รท 5.2

Control solenoid valve fixing screws (C2) . . . . . . . . . . . . . . . . . . . .

8.5 รท 10.5

0.85 รท 1.1

Propeller shaft central support retaining bolt (C) . . . . . .

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

2 1. 2. 3. 4. 5. 6. 7. 8.

Sectional view of drive gear with electrohydraulic coupling 9. Four--wheel drive engagement spring. Driven shaft. 10. Plate. Seal. 11. Circlip. Fixed sleeve. 12. Four--wheel drive engagement solenoid valve. Circlip. 13. Plug. Intermediate gear journal. 14. Solenoid valve support. Idler gear. 15. Sleeve. Driven gear. Mobile coupling.

NOTE: On installation, apply sealing compound to the surfaces X (see Section 27, Chapter 1).

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SECTION 23 -- DRIVE LINES -- CHAPTER 1

3 Sectional views of drive gear with mechanical coupling and front splined sleeve. A. L. 1. 2. 3. 4. 5. 6. 7.

Detail of propeller shafts. End float of sleeve (3). Circlip. Shim ring. Sleeve. Circlip. Intermediate gear journal. Idler gear. Bearing.

8. 9. 10. 11. 12. 13. 14. 15.

Seal. Driven shaft. Coupling sleeve. Driven gear. Spacer. External control lever. Lever return spring (13). Control pad.

NOTE: On installation, apply sealing compound to the surfaces X (see Section 27, Chapter 1).

84419869A-- 06 - 2011

SECTION 23 -- DRIVE LINES -- CHAPTER 1

DESCRIPTION AND OPERATION OF THE 4WD DRIVE GEAR WITH ELECTROHYDRAULIC COUPLING The electrohydraulically operated 4WD is engaged by pressing the switch to the right of the operator. By turning on the switch, the electrical impulse to the solenoid valve control relay is deactivated. With the solenoid valve de--energized, the oil supply to the mobile coupling internal chamber is interrupted, causing the parts to engage and the oil to drain from the control circuit.

The 4WD is disengaged by turning off the switch to the right of the operator. This sends an impulse to the relay which, in turn, energizes the control solenoid valve. With the solenoid valve energized, oil is supplied to the mobile coupling internal chamber and the 4WD disengages. Lubrication is guaranteed by the oil in the rear transmission gearbox.

DESCRIPTION AND OPERATION The drive gear housing is mounted below the rear transmission gearbox and is driven by the bevel pinion shaft via the idle gear (6, figs. 2 and . 3) Drive is then transmitted from the shaft to the front axle by means of the propeller shaft that connects the two units.

Drive gear engagement and disengagement by means of the switch to the right of the operator. A light on the control panel illuminates when the drive gear is engaged.

84419869A - 06 - 2011

SECTION 23 -- DRIVE LINES -- CHAPTER 1

ELECTROHYDRAULIC DRIVE GEAR TROUBLESHOOTING Problems FWD does not engage.

Possible causes

Solutions

1. Drive gear engage/disengage Replace switch. switch faulty. 2. Solenoid valve control contac- Check relay. Replace if tor faulty. necessary. 3. Drive gear solenoid valve con- Check solenoid valve. Replace if trol jammed in delivery position. necessary.

4WD remains engaged.

4. Spring (20, page 3) stretched.

Overhaul the unit.

1. Transmission oil level low.

Top up oil.

2. Clogged oil filter.

Replace filter.

3. Hydraulic pump faulty.

Overhaul or replace the pump.

4. Drive gear engage/disengage Replace switch. switch faulty. 5. No power at solenoid valve: Check electrical connections and connections loose, damaged or replace defective parts. contactor defective. 6. Drive gear solenoid valve con- Overhaul or replace solenoid trol jammed in discharge posi- valve. tion. 7. Oil leakage through seals, lea- Replace damaged seals. ding to drop in pressure: hub, piston or delivery union seals, or drive gear shaft seal rings. With electrohydraulic 4WD disengaged, drive cannot be engaged by operating the brake pedals.

84419869A-- 06 - 2011

1. Brake pump pressure switch Replace pressure switch. faulty.

SECTION 23 -- DRIVE LINES -- CHAPTER 1

Op. 23 101 26 PROPELLER SHAFTS AND GUARD Disassembly -- Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Unscrew the front, middle and rear screws, and detach the propeller shaft guard (1). 4 2. Remove the circlip (3) and move the sleeve (2) back to free it from the splined output shaft of the front axle (1), do this on the rear sleeve too.

5 3. Unscrew bolts (2) and remove the propeller shaft (1). 4. To re--fit the propeller shaft and relative guard, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Fit and secure the propeller shaft in position.

Fit and secure the guard.

84419869A - 06 - 2011

SECTION 23 -- DRIVE LINES -- CHAPTER 1

Op. 23 101 40 -- 23 202 50 DRIVE GEAR HOUSING Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see page 8). 2. Position a suitable container under the rear transmission, unscrew the plug (1) and drain off the oil from the transmission.

NOTE: Consider that the prescribed quantity is: 30 litres for mechanical transmissions or 35 litres for hydraulic transmissions. 3. Unscrew the retaining bolts and detach the drive housing (1). 4. To re--fit the drive gear housing, proceed as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Respect the tightening torque values prescribed on page 2.

Carefully clean the contact surfaces.

Apply the sealing compound (a bead of approximately 2 mm).

Position and secure the drive box.

Refit the transmission oil drainage plug.

Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 7).

Refill the rear transmission gearbox (for products and quantities, see Section 00, page 6).

84419869A-- 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION Chapter 1 -- Front axle mechanical transmission CONTENTS Section

Description

Page

25 000

25 100 30

Front axle. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

25 100 38

Front axle. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

25 108 46

Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

25 108 47

Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

25 102 24

Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

25 102 27

Front axle differential with LIM--SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

44 511 80

Leading drive wheels toe--in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

25 108 30

Front epicyclic final drive. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

steering, load bearing structure, pivoting at centre

Bevel gear pair -- differential Pinion--crown gear ratio 30 km/h: . . . . . . . . . . . . . . . . . . .

11/37 = 1:3.36

Pinion--crown gear ratio 40 km/h: . . . . . . . . . . . . . . . . . . .

11/31 = 1:2.81

Backlash between bevel drive teeth: . . . . . . . . .

0.13 รท 0.18

(1) Normal four--wheel drive models. (2) Automatic four--wheel drive models. (continued)

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 SPECIFICATIONS (overleaf)

Thickness of bevel pinion position adjustment spacer (11, page 7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.5 -- 2.6 -- 2.7 -- 2.8 -- 2.9 -- 3.0 -- 3.1 -- 3.2 -- 3.3 -- 3.4 -- 3.5 -3.6 -- 3.7

Thickness of bevel pinion bearing adjustment spacer rings (12) .

2.5 -- 2.55 -- 2.6 -- 2.65 -- 2.7 -2.75 -- 2.8 -- 2.85 -- 2.9 -- 2.95 -3.00 -- 3.05 -- 3.1 -- 3.15 -- 3.2 -3.25 -- 3.3 -- 3.35 -- 3.4 -- 3.45 -3.5 -- 3.55 -- 3.6 -- 3.65 -- 3.7 -3.75 -- 3.8 -- 3.85 -- 3.9 -- 3.95 -4.00 -- 4.05 -- 4.1 -- 4.15 -- 4.2 -4.25 -- 4.3 -- 4.35 -- 4.4 -- 4.45 -4.5 -- 4.55 -- 4.6 -- 4.65 -- 4.7 -4.75 -- 4.8

Clearance between sides of sun and planet pinion teeth . . . . . . .

0.15

Thickness of planet pinion thrust washers . . . . . . . . . . . . . . . . . . . .

1.470 ÷ 1.530

Thickness of side gear thrust washers (1) . . . . . . . . . . . . . . . . . . . .

1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0

Diameter of cross pin (14) for planet pinions . . . . . . . . . . . . . . . . .

21.939 ÷ 21.960

Side pinion cross pin bore diameter (3) . . . . . . . . . . . . . . . . . . . . . .

22.040 ÷ 22.061

Assembly clearance between cross pin and bores . . . . . . . . . . . .

0.080 ÷ 0.122

Diameter of outer axle shafts (7, page 7) in correspondence with bushes (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.975 ÷ 45.000

Inside diameter of installed bushes (8) . . . . . . . . . . . . . . . . . . . . . .

45.100 ÷ 45.175(1)

Clearance between axle shafts and bushes . . . . . . . . . . . . . . . . . .

0.100 ÷ 0.200

Interference fit between bushes and respective bores . . . . . . . . .

0.064 ÷ 0.129

Thickness of steering knuckle bearing adjuster plates (10) . . . . .

0.10 -- 0.15 -- 0.20 -- 0.25 -- 0.30

Axle--shafts and swivel assemblies

Planetary final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of driven gears thrust rings (9, page 7) . . . . . . . . . . . . .

12 : 12 + 60 = 1 : 6 mm

0.77 ÷ 0.83

Axle clearance on pivot between body and support . . . . . . . . . . . .

0.3 ÷ 1.1

Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . . . . . . .

Axle pivot

(1)

Measurement to be obtained without reaming

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

TORQUE SPECIFICATIONS

PARTS TO BE TIGHTENED

Thread

Tightening torque Nm

kgm

Front axle Crown wheel to differential gearbox retaining bolt (C1, page 4) . .

M 12 x 1.25

119 ÷ 144

12.1 ÷ 14.7

Differential lock device retaining bolt (C2) . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

60 ÷ 70

6.1 ÷ 7.1

Differential bevel gear support to axle casing retaining bolt (C3) .

M 12 x 1.25

119 ÷ 144

12.1 ÷ 14.7

Bevel pinion shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 35 x 1.5

380 ÷ 420

38.7 ÷ 42.8

Steering knuckle pin retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

55 ÷ 67

5.6 ÷ 6.8

Wheel hub bearing locknut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 70 x 2

392

Epicyclic final drive housing retaining bolt (C7) . . . . . . . . . . . . . . . .

M 10 x 1.25

55 ÷ 67

5.6 ÷ 6.8

Front axle support to engine retaining bolt (C8) . . . . . . . . . . . . . . .

M 18 x 1.5

310 ÷ 380

31.6 ÷ 38.7

Front axle pivot front and rear supports retaining bolt (C9) . . . . . .

M 18 x 1.5

370 ÷ 410

37.7 ÷ 41.8

Differential housing support cap retaining bolt (C10) . . . . . . . . . . .

M 12 x 1.25

119 ÷ 144

12.1 ÷ 14.7

Ring nut fastening the steering control hydraulic cylinder to the front axle (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

630 ÷ 670

64.2 ÷ 68.3

Bolt retaining steering control linkage ball joint (C12) . . . . . . . . . . .

242 ÷ 299

24.6 ÷ 30.5

Rim to disk retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

170 ÷ 208

17.3 ÷ 21.2

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 TORQUE SPECIFICATIONS

C5 55รท67Nm

C6 -- 392 Nm

26125

C7 55รท67Nm

380 รท 420 Nm

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Front axle overhaul stand.

380000227

Front differential unit removal-installation hook.

380000255

Front axle differential overhaul support.

casing

X 380000252

Wrench for front differential case bearing threaded adjustment ring.

X 380000286

Wheel hub seal splining tool (for axle with brake).

X 380000287

Wheel hub seal splining tool (for axle without brake).

X 380000295

Wrench for front axle wheel hub bearing retaining nut (only for standard models without brake).

X 380000265

Front axle pivot pin removal tool.

X 380000234

Front axle pivot bearing outer ring removal tool.

X 380000235

Tool for measurement of rolling drag torque of front axle bearings.

380000240

Universal kit for testing oil pressure for front axle differential lock engagement (with 380000618 and 380000613).

X 380000268

Wrench for front bevel drive pinion ring nut.

X 380000248

Bevel pinion bearing adjustment tool (with 50118).

50169

X 380000257

Front bevel drive pinion retaining wrench.

Pins (M 12 x 1.25) for front axle reduction gear cover.

50165

380000249

Universal gauge for positioning of front bevel drive pinion.

Pins (M 16 x 1.25) for front axle wheels disassembly/assembly.

Tool to be made for adjustment of bevel drive pinion; to be used in conjunction with tool 380000248 (mark tool No. 50118 -- measurements in mm). Make in UNI C40 material.

26135

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

10 26128

3 Cross--sectional views of front axle H4 = 95 mm. Nominal distance between crown wheel axis and greater diameter of the pinion. 1. Thickness of sun pinion thrust washers. 2. Sun pinions. 3. Differential gears. 4. Bevel crown wheel bearing adjustment shims. 5. Differential lock disengagement spring. 6. Differential lock control piston. 7. Axle shaft.

8. 9. 10. 11. 12. 13. 14. 15.

Axle shaft bush (7). Epicyclic reduction unit driven gear shims. Steering knuckle adjustment plates. Thickness of bevel pinion position adjustment spacer. Thickness of bevel pinion bearing adjustment spacer. Seal. Cross pin for side pinions. Crown wheel bearing adjustment ring nut.

Note -- On assembly apply a bead of sealing compound to the surfaces X as indicated on page 28.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4 Cross--sectional views of front axle pivot 1. 2.

Axle pivot front bush. Front thrust washer.

4. 5.

Rear thrust washer. Rear bush installed on axle support.

Axle pivot front pin.

Rear bush installed on bevel drive--differential support.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 25 100 30 FRONT AXLE ASSEMBLY Removal--Installation

Note -- The front axle assembly can be removed from the tractor either with or without previously removing the drive shaft. The description below refers to removal of the front axle with the drive shaft installed on the tractor. For removal of the drive shaft refer to section 23. 1. Unscrew the fixing screws (1) and remove the front wheel mudguards (if applicable). Do this on both sides. 2. Carry out operation 90 100 22 -- Bonnet (perform removal only). NOTE: This operation is not strictly necessary but it is advised to avoid damaging the bonnet.

5 3. Extract the fixing pin and remove the ballast weights (1); unscrew the fixing screws and recover the ballast support (2).

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Unscrew the front, middle and rear fasteners, and detach the propeller shaft guard (1).

7 5. Remove the circlip (3) and move the sleeve (2) back to free it from the splined output shaft of the front axle (1), do this on the rear sleeve too.

8 6. Unscrew bolts (2) and remove the propeller shaft (1).

9 7. Using chains (1) or nylon ropes, connect the front axle to the hoist, lift the front part of the tractor and position a fixed stand under the engine sump. Detach the two front wheels.

10 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

8. Disconnect the steering cylinder control pipes (1).

11 9. Unscrew the relevant front (1) and rear (2) bearing support fixing screws of the front axle.

12 10. Detach the front axle (1) from the relevant support. 11. To assemble the front axle, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Adhere to the torque setting values prescribed on page 3.

Position the front axle and secure it with the rear and front bearing supports.

Connect the steering cylinder control piping.

Position and secure the front wheels.

Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.

Position the propeller shaft guard and secure it.

Position and secure the ballast support.

84419869A - 06 - 2011

13 --

Carry out operation 90 100 22 -- Bonnet (perform installation only).

Position and secure the front wheel mudguards, if applicable (carry out this operation on both sides).

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 25 100 38 FRONT AXLE Disassembly--Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Note -- Front axle overhaul operations must be carried out on stand No. 380000251.

25587

14 1. Unscrew the plug (1) and drain the oil from the axle casing.

1 25588

15 2. Unscrew the plug (1) on the left--hand epicyclic final drive housing; repeat the same operation on the right--hand housing.

25589

16 3. Remove the front axle rear support (1); remove the front support and washer.

25590

17 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Unscrew the left--hand final drive cover (1) retaining bolts. Tighten two pins 50169 (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).

25594

18 5. Remove the driving gear stop (2) circlip (1).

25595

19 6. Remove the driving gear stop (1) circlip (2, fig. 19).

25596

20 7. Remove the securing ring (1) on the wheel hub bearing lock ring (2).

25597

21 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

8. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).

25598

22 9. Remove the wheel hub (1) together with the epicyclic crown (2). Recover all disassembled parts.

25599

23 10. Unscrew the three stub axle lower pin retaining bolts (1). Recover the lower pivot pin and the relative adjusting spacers.

25600

24 11. Unscrew the three mudguard support (2) retaining bolts (1).

25601

25 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

12. Extract the upper pivot pin (1) and remove the stub axle (2). Recover all disassembled parts.

25602

26 13. Unscrew the retaining bolt (2) of the axle shaft (1).

25603

27 14. Using a crowbar, remove the axle shaft (1, fig. 27). 15. To disassemble the right hand side gear unit, observe the order of operations used for the disassembly of the left hand side gear unit, from operation No. 7 to operation No. 17.

25604

28 16. Unscrew the bracket (1), loosen the union (3) and remove the differential lock control rigid pipe (2).

25605

29 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 17. Unscrew the two bevel drive--differential support retaining bolts from the axle casing, screw on the two pins 50169 (1). Remove the remaining bolts and the bevel drive--differential support, attach a chain (2) and put the hoist under strain. Remove the bevel drive--differential support (3) from the axle casing.

25606

30 18. Fit tool 380000255 (1) in the vice on a work bench, lock the bevel drive--differential support in the tool and remove the chain.

19. Unscrew the screw (2) and retrieve the ring nut locking plate (3). Do this on both sides.

25607

31 20. Unscrew the bevel drive--differential support cap (1) retaining bolts (2) and remove.

25612

32 21. Remove the crown wheel--differential unit (2) from the casing (1).

25613

33 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

22. Remove the circlip (1) from the splined shaft (2)..

25614

34 23. Straighten the staking on the splined shaft lock nut (1).

25615

35 24. Unscrew the nut using wrench 380000268 (1) while preventing rotation of the bevel drive pinion shaft using wrench 380000257.

25616

36 25. Remove the splined shaft stop ball (1).

25617

37 84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

26. Acting on the rear part, extract the bevel pinion shaft (1) and recover the spacer, adjusting shims and the bearing.

25618

38 27. Using a screwdriver, detach and recover the dust seal, the oil seal (1) and the rear bearing..

25619

39 28. To assemble the front axle, proceed as follows

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

For the correct orientation of the various parts, refer to the illustrations on page 7.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Respect the tightening torque values prescribed on page 3.

Carry out the adjustments described on pages 27 รท 36.

Fit the rear bearing, seal, dust seal, adjusting shims, spacer and bevel pinion shaft, complete with front bearing.

Position the stop ball, tighten and secure the bevel drive nut, then position the circlip.

Assemble the crown wheel--differential unit and support caps and tighten the relative screws.

Assemble the differential lock sleeve and relative stop ring.

Assemble the differential lock control piston, spring, bell housing and tighten the relative bolts, then fit the ring nut locking plate and differential lock internal pipe.

Reconnect the bevel drive--differential support to the front axle casing and fit the differential lock external pipe.

Fit the axle shaft and screw

Fit the stub axle, the adjustment shims, the upper and lower pivot pins, the mudguard bracket and related bolts.

Fit the wheel hub, final drive crown wheel and ring nut and tighten to the prescribed torque whilst rotating the hub to settle the bearings.

Fit the snap rings, drive gear and final drive cover.

Fit the front and rear supports and the oil drainage plugs.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 25 108 46 or 25 108 47 STEERING KNUCKLE PINS AND BEARINGS Replace

ATTENTION Handle all parts with carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. If steering knuckle pivot pins present problems during disassembly operations, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Fit the central tie bolt (4) screwing it fully into the grease nipple bore on the pin (6).

24596

5. Screw in the nut (3) to drive the pin out of its bore.

40 6. Using extractor tool 380000234 (1) remove the steering knuckle bearings.

7. Re--install the steering swivel bearings using a suitable drift.

24599

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

Carry out the following adjustments.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

STUB AXLE ADJUSTMENT Proceed as follows.

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

8. Apply AMBRA GR 9 grease on the outer races of the bearings and fit the upper cover, without the adjustment plate, but with tool 380000235 (2). Tighten the cap bolts (C5, page 3) to a torque value of 55 รท 67 Nm (5.6 รท 6.8 kgm).

24076

42 9. Fit the lower cover without the adjustment plate and lubricate the three retaining bolts with engine oil. 10. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow excess grease to escape.

24077

43 11. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing is 2.9 Nm (0.3 kgm) (with a torque increase of 0.98 Nm -- 0.1 kgm) without considering the peak starting value. If not, adjust by way of the lower cover bolts.

12. Measure the gap (H) created between the lower cover and the casing in correspondence with the three bolts.

24078

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

13. Calculate the average of the three values measured. The total thickness of the adjustment plates (10, page 7) to be fitted under the lower cover will be given by:

S3= H

24079

If necessary, round the value off to the next 0.05 mm.

10 45

14. Partially unscrew the screws of the lower cover, insert the plate (10, page 7) and tighten the screws (C5, page 3) to a torque of 55 รท 67 Nm (5.6 รท 6.8 kgm).

15. Check that the torque necessary to rotate the casing is 2.9 รท 7.8 Nm (0.3 รท 0.8 kgm) without considering the initial peak torque.

16. If the torque value measured is greater than the specified value, increase the thickness of the shims, if it is less than the specified value, reduce the thickness of the shims.

17. Fit the grease nipples in the upper and lower covers and grease the assembly.

84419869A - 06 - 2011

SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive shaft bearings (12, page 6).

ATTENTION

Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Clamp tool 380000248 (1) in the vice, install the inner rings on the bearings (2 and 4), the spacer (3) and fully tighten the nut on the tool. Note -- insert tool 50118 (see page 5) between tool 380000248 (1) and the bearing (2).

24584

46 2. Using the micrometer, measure the distance (H1) between the upper surface and the pin of tool 380000248 (1). 3. Disassemble the parts mentioned above and lubricate the bearings with engine oil. Reassemble the parts, excluding the spacer (3, fig. 46), in the bevel drive--differential housing, using tool 380000255, complete with outer bearing races, held in the vice.

24585

47 4. Fully tighten the nut on the tool 380000248 (1) (see Note above) whilst turning the tool to ensure that the bearings are seated correctly. 5. Using the micrometer, measure the distance (H2) shown by the tool in this condition. 6. The thickness of the adjustment shim (12, page 7) required is given by: S = H2 -- H1 + 0.05 mm

24586

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

If necessary, round the adjustment shim (12) value up to the nearest 0.05 mm. Note -- On completing the adjustment, do not remove the adjustment tool from the bevel drive--differential housing: leave in place for adjustment of the bevel pinion position. Determining the thickness of the bevel pinion position adjustment shim (11, page 6). Proceed as follows. 7. Fit tool 380000249 (1) in the bevel drive--differential housing, complete with outer bearing rings, crown wheel bearings adjustment shim, circlip and differential housing caps. 8. Screw the cones (3) of tool 380000249 (1) in or out in order to position the micrometer shaft in the direction of the inner bearing ring (2) and eliminate end float between the cones and the outer rings of the bevel crown wheel bearings. 9. Adjust the micrometer so that the shaft is in contact with the inner bearing ring (2) and measure the distance (H3). 10. Determine the correct distance (H5) between the crown wheel axis and the large diameter base of the pinion: H5 = H4 Âą C where: H4 = 95 mm. Nominal distance between the crown wheel axis and the large diameter base of the pinion (see page 7). C = correction value stamped on pinion preceded by a + or -- sign (if other than 0), to be added to or subtracted from the nominal distance (H4) according to the sign. 11. The thickness of the adjustment ring (11, page 7) will be given by:

24588

S = H3 -- H5 where: H3 = the distance measured using the micrometer; H5 = corrected nominal distance between the crown wheel axis and the large diameter base of the pinion.

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Example --

Distance measured using micrometer H5 = 98 mm.

Nominal distance between crown wheel axis and large diameter base of H4 = 95 mm.

Correction value C = + 0.2 mm.

Corrected nominal distance H5 = 95 + 0.2 = 95.2 mm

Thickness of adjustment shim S = 98 -- 95.2 = 2.8 mm.

Correction value C = -- 0.2 mm.

Corrected nominal distance H5 = 95 -- 0.2 = 94.8 mm.

Thickness of adjustment shim S = 98 -- 94.8 = 3.2 mm.

Correction value C = 0 mm.

Corrected nominal distance H5 = H4 = 95 mm.

Thickness of adjustment shim S = 98 -- 95 = 3 mm.

12. Remove tools 380000248 and 380000249 from the bevel drive housing.

13. Fit the drive pinion complete with: inner bearing rings, spacer and pre--determined adjustment shims (11 and 12). 14. Fit the O--ring (1) on the bevel pinion shaft. 15. Insert the spacer on the pinion and, after having carefully greased the outer surface, fit the anti--rotation ball.

24589

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

16. Fit pinion retaining tool 380000257 (2).

17. Insert wrench 380000268 on the adjuster ring nut.

1 18. Using the torque wrench on the pinion retaining wrench (2), hold the bevel pinion in position and, using a torque wrench (positioned as in the figure) on the ring nut wrench (1), tighten the ring nut (C3, page 3) to a torque of 380 ÷ 420 Nm (38.7 ÷ 42.7 kgm), whilst rotating the pinion shaft to ensure perfect bearing fit.

24590

19. With torque wrench 380001633 (1) fitted on pinion retaining wrench 380000257 (2), check that the pinion rolling torque, without oil seal (13, page 6) and relative dust seal, is 0.8 ÷ 1.3 Nm (0.080 ÷ 0.130 kgm). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (12, page 7), if the torque is greater than the prescribed value, fit a thicker adjustment shim.

20. Unscrew the ring nut and fit the seal (13, page 6) and the relative dust seal ring. Tighten the nut to a torque value of 380 ÷ 420 Nm (38.7 ÷ 42.7 kgm) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.

21. With torque wrench 380001633 (1) fitted on pinion retaining wrench 380000257 (2) check that the pinion rolling torque, with oil seal and relative dust seal, is 0.6 ÷ 1.5 Nm (0.060 ÷ 0.150 kgm). Finally, secure the ring nut and fit the snap ring on the bevel pinion shaft

24587

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Adjusting the ring bevel gear bearings and checking the clearance between the teeth of the bevel gear pair. Proceed as follows. 24112

22. Install the differential assembly complete with crown wheel and inner bearing rings on the differential bevel drive support.

24112

53 23. Insert the outer rings on the bevel drive--differential support, install the differential support caps, tighten the relative bolts to a torque value of 59 Nm (6 kgm), then loosen and re--tighten to a torque of 20 Nm (2 kgm).

24. Fit the adjuster shim (4, page 6), that was previously removed during the axle overhaul operation, and the relative circlip.

24591

54 25. With the bearings perfectly lubricated, rotate the crown wheel and, at the same time, tighten the ring nut using wrench 380000252 (1) to a torque value of 39 ÷ 59 Nm (4 ÷ 6 kgm) to take up the axial play between the components.

26. Measure the backlash between pinion and crown wheel, using a 1/100 dial gauge perpendicular to the outer edge of a tooth on the crown wheel (1, fig. 56).

24592

55 27. Repeat the measurement in a further two positions 120° apart and compare the average of the three values (Gm) with the prescribed normal backlash: 0.13 ÷ 0.18 mm average value 0.15 mm. If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim (4, page 6).

24593

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Note -- On standard models (fitting without differential lock) if the clearance value is not within the prescribed field of tolerance, unscrew one of the ring nuts, whilst tightening the other to an equal amount, so as to reset the prescribed clearance. The definitive value (4, page 6) to fit on the bevel drive--differential support will be given by: S = Sp -- {(Gm -- 0.15 ) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing; Gm = average backlash measured between the sides of the teeth of the bevel drive. If the backlash measured is less than the prescribed value, it will be necessary to fit a thicker adjustment shim (4, page 6) the value being given by: S = Sp + {(0.15 -- Gm ) x 1.35} where: Sp = thickness of test shim installed in the bevel drive--differential housing; Gm = average backlash measured between the sides of the teeth of the bevel drive. 28. Fit a shim (4, page 6) of the calculated thickness and with a 1/100 scale dial gauge positioned perpendicular to the outside edge of one of the crown wheel teeth, check that the backlash between the pinion and the crown wheel is within the prescribed tolerance limits 0.13 รท 0.18 mm. 29. Using wrench 380000252 (1) turn the adjustment ring nut and:

1 24592

57 check using torque wrench 380001633 (1), that the rolling resistance torque of the crown wheel and pinion bearings, as measured in the same conditions used to check only the pinion, is: A2 = A1 + 1 รท 1.5 Nm (0.10 รท 0.15 kgm) where: A2 = pinion--crown wheel rolling resistance torque; A1 = rolling resistance torque of pinion only as previously measured;

24594

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 1 รท 1.5 Nm (0.10 รท 0.15 kgm) = rolling resistance torque of crown wheel only measured at the end of the pinion, using wrench 380000257 and torque wrench 380001633.

30. Tighten the cap bolts ( C10, page 3) to a torque value of 119 รท 144 Nm (12.1 รท 14.7 kgm). 31. Fit the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch.

32. Attach the bevel drive--differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound (approx. 2 mm) along the marked line shown in the drawing below.

24591

Sealing compound application diagram for assembly of bevel drive unit and epicyclic final drive unit. The types of mastic to use are listed on page 1 of section 00.

24595

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 25 102 24 FRONT AXLE DIFFERENTIAL Overhaul When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of the planet pinions and the side gears.

Proceed as follows. 1. Thoroughly clean the components of the differential to remove any traces of oil that would otherwise prevent accurate backlash measurement.

2. Fit the two sun gears without thrust washers on the differential casing.

3. Fit the planet pinions complete with thrust washers and pins and screw down the pin retaining bolts by a few turns to hold the pins in place. 4. Position a dial gauge on the differential housing. 24597

5. Move the left--hand side gear to bring it into full contact with the planet pinion and then push it up against the differential housing, reading the endfloat (Gs) on the dial gauge.

6. Repeat the above operations to measure the endfloat on the right hand side gear (Gd). The side gear endfloat will be 0.15 mm. Therefore the rings to be inserted in the differential housing are given by: Ss = Gs -- 0.15 mm for the left--hand side gear; Sd = Gd -- 0.15 mm for the right--hand side gear. 7. Install shims as near as possible to the calculated value and, using a dial gauge and following the previously described procedure, check that the endfloat of the left-- and right--hand sun gears is approximately 0.15 mm.

24598

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

LIM--SLIP SELF--LOCKING DIFFERENTIAL LOCK Operation The differential with limited slip locking (LIM -- SLIP) is of the two planet gear--type, provided with two multi--disk clutch assemblies fitted between the side gears and the differential casing. This differential lock device is totally automatic, requires no manual operation and notably reduces (without completely eliminating) wheel slipping that may result fom tractor grip loss. The difference in speed between the side gears and the differential casing when a wheel loses grip and begins to slip, is prevented by the clutch assemblies that are compressed by axial thrust from the bevel drive torque transmitted to the side gears by means of the teeth on the two planet gears. These torque values may be different, according to the nature of the ground and the route followed by the tractor, and may vary in intensity thereby proportionally determining the axial stress on the clutches, allowing the sun gears to mesh with the differential casing which, in turn, permits the axle to overcome the unevenness of the ground.

27966

63 LIM--SLIP self--locking differential

Op. 25 102 27 FRONT AXLE DIFFERENTIAL WITH LIM--SLIP UNIT Overhaul

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Remove the bevel drive--differential casing assembly from the front axle, attach to support 380000255 (4), lock in a vice and proceed with disassembly operations as follows. 2. Remove the bolts (2) and the right--hand (Gd) and left--hand ring nut lock plates (3). 3. Check that the right-- and left--hand caps (1) are marked so as not to interchange them during assembly. 4. Remove the right and left--hand bearing adjustment ring nuts (Gd) from the bevel crown wheel. 5. Remove the bolts (C9), and caps (1) and separate the crown wheel from the bevel pinion support. 6. If necessary, unscrew the retaining bolts (C1, page 4) and remove the crown wheel.

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Disassemble the LlM--SLlP self--locking differential Iock as follows: 7. Remove the retaining bolts (1) from the differential half--casing. 8. Open the differential casing (6). 9. Remove the differential pin (4), complete with the planet gears (3), the shims (2) and the retaining pin (9) from the half--casing (7). 10. Remove the side gear (5), the friction disk (11), the metal disks (10) and the friction disks (12). 11. Remove the side gear (5), friction disk (11), metal disks (10) and the friction disks (12) from the half--casing (8). 12. Check the wear on the metal disks (10) and the friction disks (11 and 12, see table below), replacing parts that are near their wear limit. 13. Proceed with self--locking differential assembly operations, carrying out the previously described operations in reverse order, apply LOCTITE 270 to the threads on the screws (1) and tighten to a torque value of 50 Nm (5.1 kgm).

27966

LIM--SLIP self--locking differential

14. Refit the bevel crown wheel (if previously disassembled) on the half--casing (8), tightening the bolts (C1, page 4) to a torque value of 113 Nm (11.5 kgm). 15. Check the rolling torque of the bevel pinion, as indicated on page 32. 16. Assemble the crown wheel, complete with LIM--SLIP self--locking differential lock, on the bevel drive support, remembering to fit the previously marked crown wheel bearing support caps in the correct order and assemble and adjust the crown wheel bearings as indicated on page 34.

z 27967

66 Friction parts detail

LIM--SLIP SELF -- locking differential lock friction discs Part no.

Description

Quantity

Thickness mm

Maximum wear per disc mm

Metal disk

1.5

Friction disk

2.8

0.10

Friction disk

1.6

0.15

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 44 511 80 LEADING DRIVE WHEELS TOE--IN CHECK When travelling in a straight line, the wheels on four--wheel drive models must be parallel to the longitudinal axis of the tractor. A slight toe--in of the front wheels is permissible -- up to a maximum of 6 mm, as measured at the edges of the wheel rims. To check the exact value of the toe--in setting of four--wheel drive tractors, proceed as follows. 1. Inflate the front tyres to the specified pressure. 2. Position the steering at half--lock with a straight--edge along the longitudinal axis of the tractor. 3. Check that the wheels are parallel to the longitudinal axis of the tractor. 4. Check that the distance (L) between the ball joint (1) and the end of the cylinder (2) is the same on both sides of the steering control cylinder (2). 67 5. Measure the distance (1) between the front inside edges of the rims.

6. Turn both front wheels through 180o then, at the height of the wheel hub centres, measure the distance (2) between the rear inside edges of the wheel rims, checking that the new measurement is equal to or greater than distance (1) by a maximum of 6 mm. The rotation of the wheels through 180o is required in order to eliminate the effect on the measurement of any eventual wear on the rims.

24666

68 7. If wheel toe--in needs to be adjusted, unscrew the lock nut (1) and screw the ball joint (2) in or out to obtain the prescribed toe--in. During this operation, it is necessary to check that the distance (L, fig. 67) stays the same on both sides of the steering control cylinder (2, fig. 67). After having adjusted the toe--in to within the prescribed limits, tighten lock nut (1).

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE Disassembly -- Assembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Front epicyclic final drive removal and installation can be carried out with the axle detached and positioned on the stand 380000251, or with the axle fitted on the tractor. If the operation is performed with the axle fitted on the tractor, a support stand must be positioned under the engine sump.

25587

Proceed as follows. 1. Unscrew the plug (1) and drain the oil from the epicyclic final drive casing.

25589

2 2. Unscrew the left--hand final drive cover (1) retaining bolts. Tighten two pins 50169 (2) and, using an extracting tool screwed into the oil drainage plug hole, remove the cover (1).

25594

3 3. Remove the securing ring (1) on the wheel hub bearing lock ring (2).

25597

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SECTION 25 -- FRONT AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).

1 25598

25598

5 5. Remove the wheel hub (1) together with the epicyclic crown (2). Recover all disassembled parts.

6. To refit the front epicyclic final drive, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Refer to the illustrations on page 6 for the correct orientation of the various parts.

Adhere to the torque setting values prescribed on page 3.

Assemble the wheel hub and the epicyclic final drive fixed gear.

Progressively tighten the ring nut, using the torque wrench and wrench 380000295 (1) to obtain a torque value of 392 Nm (40 kgm); at the same time, rotate the wheel hub to ensure that the bearings are correctly seated.

Carefully secure the ring nut.

Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 2 mm) along the marked line shown on page 28.

Assemble the epicyclic final drive casing, complete with gears.

Fill up the front epicyclic final drive (for recommended products and quantities see page 6, Section 00).

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25599

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION Chapter 1 -- Rear axle mechanical transmission CONTENTS Section

Description

Page

27 000

27 106 16

Rear transmission casing. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

27 120 10

Right--hand final drive casing. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

27 120 20

Left--hand final drive casing. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL 9/44 = 1:4.9(1)

Bevel drive gear ratio: Clearance between sides of bevel gear pair teeth . . . . . . . . . .

11/45 = 1:4.1(2)

0.15 ÷ 0.20

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

with two side pinions

Mechanically controlled differential lock . . . . . . . . . . . . . . . . . . .

by means of pedal

Side pinion internal seat diameter (5, fig. 8) . . . . . . . . . . . . . . .

24.040 ÷ 24.061

Side pinion pin diameter(19, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . .

23.939 ÷ 23.960

Clearance between side pinions and pin . . . . . . . . . . . . . . . . . .

0.080 ÷ 0.122

Diameter of crown wheel pinion hub seats on differential housing (3, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.080 ÷ 44.119

Diameter of crown wheel pinion hubs (17, fig. 8) . . . . . . . . . . .

43.961 ÷ 44.000

Clearance between crown wheel pinion hubs and seats . . . . .

0.080 ÷ 0.158

Bevel gear bearing adjustment and bevel pinion clearance . . Thickness of bearing adjuster rings and bevel gear clearance (21, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (1)

30 km/h model --

(2)

40 km/h model.

see pages 14 ÷ 15 mm

0.15 -- 0.20 -- 0.50 (continued)

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 MAIN SPECIFICATION OF BEVEL GEAR PAIR AND DIFFERENTIAL (overleaf)

Clearance between sides of sun and planet pinion teeth

0.18 รท 0.25

Thickness of differential crown wheel shim adjustment rings (16, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm 1.4 -- 1.5 -- 1.6 -- 1.7 -- 1.8 -- 1.9 -- 2.0

Thickness of differential side pinion shim adjustment rings (4, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.470 รท 1.530

Adjustment of the clearance between the sun and planet pinion teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see pages 15 and 16

Adjustment of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 13

Thickness of differential lock control fork adjuster . . . . . . . . . .

0.5

220

Differential lock control fork spring (Mechanical control): --

spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

length of spring under a load of 177 รท 195 N (18.1 รท 19.9 kg) mm

157.5

FINAL DRIVE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

epicyclic with three side pinions with straight toothing

Adjusting end float of side pinion casing . . . . . . . . . . . . . Thickness of axial clearance adjuster rings for side pinion casing (10, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

84419869A - 06 - 2011

see page 22 mm

0.15

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Final drive casing fixing screws or nuts (C1, fig. 1) . . . . . . . . . . . . .

Tightening torque Nm

kgm

117 ÷ 129

11.9 ÷ 13

Service brake control assembly retaining bolts (C2) . . . . . . . . . . . .

60 ÷ 75

6.1 ÷ 7.6

Final drive gear retaining bolts (C3) . . . . . . . . . . . . . . . . . . . . . . . . . .

41 ÷ 51

4.2 ÷ 5.2

Transmission shaft bearings support fixing screws (C1, fig. 2) . . .

84 ÷ 93

8.6 ÷ 9.5

PTO casing retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

73 ÷ 90

7.4 ÷ 9.2

PTO driven shaft ring nut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

280 ÷ 309

28.5 ÷ 31.5

Transmission casing plug (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ÷ 25

2.0 ÷ 2.5

Drive gear housing retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . . . .

41 ÷ 51

4.2 ÷ 5.2

Bevel pinion shaft ring nut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

280 ÷ 309

28.5 ÷ 31.5

Transmission bearings guard screws (C7) . . . . . . . . . . . . . . . . . . . . .

20 ÷ 25

2.0 ÷ 2.5

Retaining bolts securing transmission casing to clutch casing (C8)

117 ÷ 129

11.9 ÷ 13

Differential lock control external lever retaining bolt (C9) . . . . . . . .

43 ÷ 51

4.4 ÷ 5.2

Crown wheel to differential gearbox retaining bolt (C10)

76 ÷ 84

7.7 ÷ 8.6

Crown wheel and pinion support bearing ring nut retaining bolt (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20 ÷ 25

2.0 ÷ 2.5

1 84419869A - 06 - 2011

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 TORQUE SPECIFICATIONS

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

List of specific tools required for the various operations described in this section. 380000227

Clutch casing lift hook.

380000301

Turning stand for overhaul.

380001626

Grooved wrench for bevel gear.

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

3 Longitudinal section of gearbox--transmission 1. 2. 3. 4. 5. 6. 7.

Transmission input shaft. PTO control shaft. 3rd and 4th gear engagement synchronizer. Range output shaft. Selector sleeve for low speeds. Low speed drive gear. Bevel pinion shaft.

84419869A - 06 - 2011

8. 9. 10. 11. 12. 13. 14.

Crown wheel. Bevel pinion shaft support bearings Driven gear for low speeds and drive control. Pinion shaft retaining ring nut. Low and medium speed control gear. Medium and fast speed engagement sleeve. 1st and 2nd gear engagement synchronizer.

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4 Sectional view of transmission 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Side gear. Differential pinion. Side pinion pin (2). Side pinion pin (5). Differential housing Differential output half shaft. Final drive gear. Final drive planet gear. Final drive planet gear carrier support. Final drive casing. Wheel axle shaft bearing.

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Seal. Wheel axle shaft. Wheel axle shaft bearing. Seal. Bevel crown wheel bearing support. Bevel crown wheel bearing support. Differential lock control external lever. Differential lock control rod. Spring. Differential lock control fork. Rod support (19).

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 DESCRIPTION AND OPERATION

The rear transmission transmits drive from the gearbox to the lateral final drives by means of the bevel gear pair. The bevel gear pair is of the helical tooth type and is supported by taper--roller bearings. The differential has two pinions and is equipped with a mechanically controlled differential lock.

The lateral final drives are of the epicyclical type and are operated by the bevel gear pair output drive shafts.

BEVEL DRIVE AND DIFFERENTIAL TROUBLESHOOTING Problems

Possible causes

Solutions

Transmission is noisy while the 1. Incorrect adjustment or wear Remove the rear transmission tractor is moving, even when the of sun and side pinions. gearbox and replace the worn parts, gears are in neutral (not due to then correctly adjust the differential final drives). gear clearance (page 24). 2. Excessive clearance between Remove the rear transmission casing half--shaft keyed groove and and replace the damaged parts. sun gears. Transmission is noisy when 1. Internal part faulty. tractor is under or released from load.

Remove the rear transmission gearbox and replace the worn parts, then correctly adjust the differential gear clearance (page 24).

Transmission noisy and assembly 1. Insufficient coupling clearan- Remove the rear transmission box overheats. ce between the teeth of the pi- and correctly adjust the ring bevel nion and the ring gear. gear bearings (page 21).

FINAL DRIVE FAULT DIAGNOSIS Problems

Possible causes

Final drives are noisy while the 1. Internal part faulty. tractor is moving, even when the gears are in neutral. neutral 2. Excessive clearance between wheel axle shaft spline and epicyclic final drives.

84419869A - 06 - 2011

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

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 27 106 16 REAR TRANSMISSION GEARBOX Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the rear transmission box detached from the clutch casing (see Op. 21 118 10 -- 21 118 12). To remove the gearbox, proceed as follows. 1. Carry out operation 21 118 85 Gearbox transmission casing, only removal of gearbox from casing (see Sect. 21, chapter 1). 2. Unscrew the lubrication pipe retaining bolt (1).

5 3. Remove the retaining pin (1) from the differential lock fork (2).

6 4. Unscrew the retaining bolts and detach the differential lock lever (1).

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

5. Extract the differential lock rod (3) recovering the fork (2) and the spring (1). 6. Recover the lubrication pipe (1, fig. 5).

8 7. Unscrew the relevant fixing screws and detach the right--hand bearing support (1) of the bevel crown wheel and recover it together with the differential.

9 8. Remove the stake mark of the washer (1) for the bevel pinion nut, remove the rear circlip (2) from the bevel pinion shaft and extract the sleeve (3) 9. Remove the circlip retaining the fast and slow speeds, unscrew the bevel pinion shaft nut and extract it recovering the reduction gears. 10. Detach the medium speed drive gear (1).

10 11. To refit the various parts in the rear transmission gearbox, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---

Position and secure the medium speed drive gear. Insert the bevel pinion and tighten the relevant nut to the prescribed torque, stake the washer.

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Insert and secure the gears of the reduction unit.

Position the bevel crown wheel together with the differential and lock it by means of the right--hand support.

Position and secure the differential lock control lever.

Block the fork governing the differential lock using the relevant circlip.

Insert the bevel crown wheel together with the differential and secure it by means of the right--hand support, make the adjustments described on page 14.

Adjust the position of the differential lock engagement sleeve as described on page 13.

Block the lubrication line.

Position the lubrication line.

Position the differential lock control fork, the spring and the rod.

Carry out operation 21 118 85 Gearbox transmission casing, only assembly of gearbox from casing (see Sect. 21, chapter 1).

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Sealing compound application diagram for transmission--gear box casing The types of sealing compound to be used are shown on page 1, section 00.

12 SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

27153

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 27 110 10 Adjusting the position of the differential lock engagement sleeve

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Fit the differential lock control device or the plate without the adjuster shim. 2. Insert a feeler gauge (2) with the 2.25 รท 2.5 mm shim between the sleeve and the differential housing, so that it makes contact with the sliding surfaces of the sleeve on the housing. 3. Using a crowbar, bring the sleeve into contact with the feeler gauge and the differential casing, adjusting the fork (1) to the position of the gauge.

26018

11 4. Using a feeler gauge (1), measure the clearance between the control pin (2) and the seat on the rod (3). 5. Position the required shim under the differential lock control device and secure in position using the bolts.

26019

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Fit the bevel pinion, together with the relevant parts, and tighten the ring nut to a torque of 280 ÷ 309 Nm (28.5 ÷ 31.5 kgm). 2. Check that the pinion rolling drag torque is 0.050 ÷ 0.250 kgm, corresponding to a dynamometric force on the slow speed driven gear of 7.8 ÷ 42.2 N (0.8 ÷ 4.3 kg). 3. Tighten the left ring nut completely then unscrew it by 5 turns. 4. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Screw the right--hand ring nut (1) onto the gearbox--transmission casing. 26021

13 5. Position the right--hand ring nut on the transmission--gearbox casing and tighten it completely then unscrew it by a quarter of a turn (90°). 6. Tighten the ring nut gradually, turning the crown wheel at the same time to allow the bearings to settle, until you reach a tightening torque of 20 Nm (2 kgm). Under these conditions you should be at the position of the minimum rolling value of the bevel crown wheel bearings that is the result of the rolling torque measured for just the pinion added to the values given in the table. 7. Check that the rolling torque of the pinion and ring gear is: A + (0.100 ÷ 0.200 kgm) Where: With the torque measured for the pinion only. This torque can be measured with a dynamometer (1) and cord wrapped around the slow speed driven gear and it corresponds to a force on the dynamometer that is the result of the force measured for the single pinion plus the following values: 16.7 ÷ 34.3 N (1.7 ÷ 3.5 kg) Tighten the ring nut further to bring the safety screw onto one of the three holes, then tighten the safety screw.

84419869A - 06 - 2011

26023

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1 8. Using a dial gauge (1), check the clearance between the sides of the teeth of the bevel gear pair (four measurements at 120° and the arithmetic mean of the three readings) and compare the mean of the three values with the normal prescribed clearance: 0.15 ÷ 0.50 mm.

NOTE: The difference between the four readings must be ≤ 0.06 mm.

26026

15 Adjustment of the clearance between the sun and planet pinion teeth

5 6

With the distmantled differential on the bench, proceed as follows. 9. Fit the two crown wheels (2 and 5) without rings (1 and 6) on the differential casing. Insert the side pinions (3 and 8) complete with fifth wheel ring adjustment and pin (7); turn the retaining bolt (4) a few times to prevent the pin from sliding out.

7 8 25920

16 10. Manipulate the LH crown wheel, so that it comes into contact with the side pinion and, using a depth micrometer, measure the distance (H1), taking two diametrically opposed measurements, taking the arithmetic means of the two values measured.

H1 25921

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

11. Push the crown wheel so that it touches the differential and measure the distance (H2). 12. Repeat the same operations for the RH side gear.

25922

18 13. The axial movement of the crown wheels (2 and 5) without adjustment rings is given by:

Gs or Gd = H1 -- H2

5 6

where: Gs = axial movement of LH crown wheel; Gd = axial movement of RH crown wheel;

H1 and H2 = are the LH or RH crown wheel measurements.

The normal clearance envisaged between the sides of the side pinion and crown wheel teeth is 0.18 รท 0.25 mm. Therefore, the normal clearance and the equivalent axial movement of the side gears has an average ratio of 1:1.7. Example The axial movement of the side gears corresponding to the normal clearance is: 0.15x1.7 = 0.25 mm. Therefore the adjustment rings (1 and 6) to insert on the differential housing will be given by: Ss = Gs -- 0.25 mm (for left--hand side gear). Sd = Gd -- 0.25 mm (for right--hand side gear). Insert the adjustment rings obtaining a distance which is as close as the value thus obtained (the available values are listed on page 2).

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25920

SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 27 120 10 -- 27 120 20 RH OR LH LATERAL FINAL DRIVE HOUSING ASSEMBLY Removal--Installation

DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Carry out operation 10 216 40 -- Fuel tank (perform removal only). 2. Unscrew the relevant fixing screws and detach the anti--shake brace (1) from the left--hand final drive casing, extract the pin (2) and detach the lower lift arm (3) from the rear transmission box.

20 3. Disconnect the parking brake tie--rod (1) (ISO version). 4. Unscrew the retaining bolts and detach the fuel tank support rear bracket (2).

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

5. Disconnect the PTO control line (1).

22 6. Disconnect the rear auxiliary control valve control line (1).

23 7. Disconnect the cab ground (1).

24 8. Disconnect the service brake control piping (5).

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

9. Unscrew the screws (1) fastening the cab support bracket to the left--hand final drive casing. 10. Unscrew the bottom nut of the cab right--hand rear fixing screw.

26 11. Unscrew the relevant fixing screws, detach the footrest (1), lift the front part of the mat (2) and unscrew the cab front fixing nut. Do this on both sides.

27 12. Screw two eyebolts onto the horizontal cross member located under the rear window, using the hoist and a chain (1), lift the rear part of the cab by about 60 mm taking special care not to stretch too much: tie--rods, pipes and electric cables.

28 13. Position a suitable container under the rear transmission, unscrew the plug (1) and drain off the oil from the transmission. NOTE: Consider that the prescribed quantity is: 35 litres for mechanical transmissions or 40 litres for hydraulic transmissions.

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

14. Unscrew the nut fixing the support bracket (1) of the cab and remove it.

30 15. Position a suitable hydraulic lift under the left--hand final drive casing (1), unscrew the relevant fixing screws (2) and detach the box together with the brake. 16. To refit the final drive casing, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Before refitting the casings, supports and covers, thoroughly clean and de--grease the mating surfaces and apply a bead of sealing compound of approximately 2 mm in diameter.

Adhere to the torque setting values prescribed on page 3.

Position and secure the fuel tank support rear bracket.

Position and secure the final drive casing together with the brake.

Position the bottom lift arm and secure it by means of the relevant pin.

Position and secure the anti--shake brace.

Position and secure the cab support bracket.

Position the cab and secure it by means of the relevant nuts and bolts.

Screw the plug into the rear transmission box and fill with oil (see page 6, sect. 00 for prescribed product and quantity).

Position the mat inside the cab and secure it by means of the two footrests (one on each side).

Carry out operation 10 216 40 Fuel tank (perform installation only).

Connect the service brake line.

Connect the cab ground.

Connect the rear auxiliary control valve control line.

Connect the hydraulically engaged PTO control line.

Connect the parking brake tie--rod.

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

Op. 27 120 34 DRIVE WHEEL SHAFT Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. With the final drive casing removed from the rear transmission, proceed with disassembly as follows. 1. Remove the circlip fixing the drive wheel axle shaft,

26030

2. Extract the support (1) from the driven gears and remove the end float adjuster shim from the support

26032

33 3. Connect the gear casing (1) to a hoist (2) and raise, checking that the wheel axle leaves the housing (tap on the end of the driving gear axle with a rubber mallet to ease it out).

26033

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SECTION 27 -- REAR AXLE MECHANICAL TRANSMISSION -- CHAPTER 1

4. Remove the seal (1). 5. To refit the final drive casing, proceed as follows.

ATTENTION

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

For the positioning of the various parts refer to figures 7. 24614

35 --

Respect the tightening torque values prescribed on page 3.

Fit the seal using a suitable drift.

Assemble the drive wheel shaft.

Fit the driven gear support and the relative adjuster shim.

Fit the circlip fixing the drive wheel axle shaft.

Adjust the end float of the gear support as follows.

6. Using a dial gauge (1), check that the axial clearance of the support (2) is 0.2 รท 0.5 mm; if not, change the adjuster shim (10, fig. 8). 26034

NOTE: The adjustment shims are listed on page 2.

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

SECTION 31 -- POWER TAKE--OFF Chapter 1 -- Power Take--Off CONTENTS Section

Description

Page

31 000

SPECIFICATIONS 540 rev/min power take--off Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1) independent with respect to tractor speed or: 2) synchronized with transmission gearbox

Coupling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical or hydraulic governed by means of a hand lever located to the right of the operator

Direction of rotation (from tractor rear) . . . . . . . . . . . . . . .

clockwise

Engine speed with PTO at 540 rpm: -ISO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -North America version . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rpm rpm

1958 2160

PTO revolution speed with engine at max. power of 2300 rpm -- for 540 rpm PTO ISO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North America version . . . . . . . . . . . . . . . . . . . . . .

rpm rpm

634 575

540 rpm, gearbox synchronized, PTO revolution speed (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev wheels

13.64

540 rpm, gearbox synchronized, PTO revolution speed (4WD 40 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev wheels

Diameter of driven shaft at grooved terminal . . . . . . . . .

11.41 13/

8â&#x20AC;?

(6 grooves) (continued)

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

SPECIFICATIONS (overleaf)

540/540E rpm power take--off Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1) independent with respect to tractor speed or: 2) synchronized with transmission gearbox

Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical or hydraulic by means of hand levers located on right--hand side of operator

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

by hand lever located on right--hand side of operator

Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .

clockwise

Engine speed with PTO at 540 rpm: -ISO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -North America version . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rpm rpm

1958 2160

rpm

1592

rpm rpm rpm

634 575 780

540 rpm, gearbox synchronized, PTO revolution speed (30 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev wheels

13.64

540 rpm, gearbox synchronized, PTO revolution speed (4WD 40 km/h model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev wheels

11.41

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

PTO revolution speed with engine at max. power of 2300 rpm -- for 540 rpm PTO ISO version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . North America version . . . . . . . . . . . . . . . . . . . . . . --

PTO 540E rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of driven shaft at grooved terminal . . . . . . . . .

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13/8â&#x20AC;? (6 grooves)

SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

TORQUE SPECIFICATIONS

1 Mechanically controlled 540 r.p.m. and 540/540E r.p.m. power take--off.

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

PTO casing retaining bolts (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque Nm

kgm

M 12 x 1.25

73 ÷ 90

7.4 ÷ 9.2

Clutch retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

41 ÷ 51

4.2 ÷ 5.2

Nut locking driven gear shaft (C3, fig. 1 and fig. 2) . . . . . . . . . . . .

M 32 x 1.5

280 ÷ 309

28.5 ÷ 31.5

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1 TORQUE SPECIFICATIONS

2 Hydraulically controlled 540 r.p.m. and 540/540E r.p.m. power take--off.

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

3 Longitudinal sectional diagram of 540 rpm and 540/540E rpm PTO. A. B. 1. 2. 3. 4. 5. 6.

Sectional diagram of 540 rpm PTO. Sectional diagram of 540/540E rpm PTO. 540 rpm power take off driving shaft. 540 rpm power take off drive gear. Brake disc. Brake disc housing cover. Pin retaining brake disc spring (apply Loctite 243). 540 rpm power take off driven gear.

7. 8. 9. 10. 11. 12. 13.

Grooved terminal. Seal. Splined end bearing. Circlip. Power take--off housing. 540/540E rpm power take off driving shaft. 540/540E rpm power take off driven gear.

NOTE: When mounting apply sealing compound to surfaces X.

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

4 Longitudinal sectional diagram of 540 rpm and 540/540E rpm PTO with hydraulic control. A. B. 1. 2. 3. 4. 5. 6. 7.

Sectional diagram of 540 rpm PTO. Sectional diagram of 540/540E rpm PTO. 540 rpm power take off driving shaft. 540 rpm power take off drive gear. Clutch disc. Reaction plate. Seal. Clutch piston. Clutch housing cover.

8. 9. 10. 11. 12. 13. 14. 15.

540 rpm power take off driven gear. Grooved terminal. Seal. Splined end bearing. Circlip. Power take--off housing. 540/540E rpm power take off driving shaft. 540/540E rpm power take off driven gear.

NOTE: When mounting apply sealing compound to surfaces X.

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

DESCRIPTION AND OPERATION OF MECHANICAL PTO The PTO (1) installed on the tractor transfers motion to the transported or towed implements. Control is either directly from the engine clutch or from the gearbox clutch. Mechanically engaged/disengaged PTO devices are available in two versions: --

(standard) one speed, 540 rpm.

(optional) two 540/540E rpm.

speeds,

synchronized 5

PTO controlled directly from the engine clutch Proceed as follows: --

engage the clutch by moving the control lever (1) to position (A).

When engaged, the PTO grooved terminal rotates. In these conditions PTO operation is completely independent from the tractor travel, therefore: --

stop the tractor without stopping the power take--off;

stop the power take--off without stopping the tractor (by disengaging the power take--off clutch).

To disengage the power take--off, move the control lever (1) into position (B).

Selecting the power take--off speed of rotation. -- Move the lever (1, fig. 6) into position (B): power take--off disengaged. -- Select the speed of rotation of the splined shaft by means of the selection lever (3). -- After a few moments move the control lever (1, fig. 6) forwards into position (A) for engagement.

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SECTION 31 -- POWER TAKE--OFF -- CHAPTER 1

PTO synchronized with gearbox for mechanical gearbox models. Proceed as follows: --

move the lever (1, fig. 6) into position (B): power take--off disengaged;

with the tractor stationary, fully press the engine gear clutch pedal;

after a few moments pull the collar (2) upwards, move the operation selection lever (3) fully forwards into position (C) and release the engine transmission clutch pedal.

In this case, the power take--off receives power directly from the transmission. When the tractor is stationary, the synchronized PTO does not rotate; when shifting from forward to reverse, the direction of terminal rotation is reversed.

ATTENTION Do not engage the ground speed power take--off when the tractor is moving.

NOTE: When the PTO is not in use, keep the clutch lever (1, fig. 6) in position (B) and the operation selection lever (3, fig. 8) in position (N).

TROUBLESHOOTING FOR MECHANICAL PTO Problems

Possible causes

Solutions

Slipping with speed loss on PTO Wear of clutch disc or of engine Check the data given on the specific grooved terminal. flywheel pressure plate. pages of sect. 18, replace the worn PTO clutch lever not adjusted. parts and adjust the clutch lever. Difficulty in selecting PTO speed Stiffening of the external control or Lubricate the control cable sheath. by means of the lever. control not adjusted. Adjust the control.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

SECTION 33 -- BRAKES Chapter 1 -- Braking system CONTENTS Section

Description

Page

33 000

33 202 60

Right or left--hand brake. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

33 202 46

Braking system hydraulic pump. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SPECIFICATIONS Type: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath disk, acting on differential drive shafts

parking brake (ISO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the same disks as the service brakes

Parking brake (North American version) . . . . . . . . . . . . . . . . . .

by means of gear on bevel pinion

Controls: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydrostatic, with independent pedals (connected by means of a pin)

service brake . (North American version, with platform) . . .

mechanical, with independent pedals (connected by means of a pin)

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, by means of a hand lever

Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . Number of discs for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . -(North American version, with platform) . . . . . . . . . . . . . . . . . .

N 653 no. no.

4 3

4.7 รท 4.8

Disk thickness: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(continued)

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

SPECIFICATIONS (overleaf)

Hydrostatic control Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operating pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with 2 master cylinders independently operated by brake pedals 17.6 (18 kg/cm2)

bar

Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 14

Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 15

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Screws or nuts securing gear casing to transmission casing (C1) Brake control assembly retaining bolts (C2) . . . . . . . . .

.......

Tightening torque Nm

kgm

M12 x 1.25

117 รท 129

11.9 รท 13

60 รท 75

6.1 รท 7.6

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

2 Service brakes sectional drawings 1. 2.

Service brake discs. Service brake actuator.

3. 4.

Axle shaft. Brakes intermediate disc

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

3 Service brake sectional drawing 1. 2. 3.

Brake control fluid outlet fitting. Fitting for brake fluid tank connection pipe. Pump body.

4. 5.

Brake pump control fork. Fitting for pump balancing pipe.

DESCRIPTION AND OPERATION SERVICE BRAKES The service brakes are hydraulic with oil bath discs. The two control pumps (one for each pedal) are housed in the front section of the cab and are connected to their respective pedals by means of two rods. These pumps can be operated individually or together. If operated together, the pedals are connected by a pin. A connecting pipe between the two pumps ensures balanced braking even when the brake discs are not equally worn. The two control pumps are fed from a single reservoir positioned above the pumps.

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The brake disks (4 for each rear wheel) are located inside the final drive casing. The disks are splined on the differential drive shafts.

PARKING BRAKE The parking brake is mechanically controlled, it acts, by means of a lever mechanism, on the service brake discs (ISO version) or, by means of a gear, on the rear bevel pinion shaft (North American version). The parking brake is controlled by a specific lever positioned to the left of the operator (ISO version) or by the range gear control lever (North American version).

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

BRAKE TROUBLESHOOTING Problems Brake pedals hard to operate.

Possible causes

Solutions

1. Corresponding master cylin- Replace the brake control pumps. der seized. 2. Brake control pipes structed or pinched.

ob- Clean or replace the control pipes.

The brakes stick when the pedals 1. Brake control pump pistons Release the piston and, if necessary, locked. replace the brake control pumps. are released. 2. Master cylinders seized.

Replace the brake control pumps.

Noisy brakes.

1. Friction material on brake Replace the brake disks. disks (1, fig. 2) worn.

Pedal stroke too long.

1. Air in the brake circuit.

Bleed air from the brake circuit.

2. Brake control pumps worn.

Replace the brake control pumps.

3. Leakage from control pipes.

Eliminate the cause of the leakage.

1. Wrong tyre pressure.

Inflate tyres to correct pressure.

2. Brake control pumps worn.

Replace the brake control pumps.

Unbalanced braking.

3. Pump connection pipes Clean or replace the pipes. obstructed or pinched. 4. Brake control pipes Clean or replace the control pipes. obstructed or pinched. 5. Pump control piston seals Replace the brake control pumps. worn or damaged. 6. Friction material on brake disk Replace disk. (1, fig. 2) worn. (continued)

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

BRAKE TROUBLESHOOTING (overleaf)

Problems Inefficient braking.

Possible causes

Solutions

1. Friction material on brake Replace the brake disks. disks (1, fig. 2) worn. 2. Brake control pumps worn.

Replace the brake control pumps.

3. Air in the brake circuit.

Bleed air from the brake circuit.

4. Leakage from control pipes.

Eliminate the cause of the leakage.

5. Pump control piston seals Replace the brake control pumps. worn or damaged. Parking brake does not lock.

1. Brake control adjusted.

return The tractor remains braked when 1. Control obstructed. the parking brake is disengaged.

incorrectly Adjust correctly.

stroke Remove obstructions.

2. Actuators (2, fig. 2) seized on Release and replace the damaged brake disks. parts.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

Op. 33 202 60 RIGHT OR LEFT HAND BRAKE Removal--Installation

DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that assemblies or parts are supported by means of suitable slings and hooks. Ensure that no--one is in the vicinity of the load to be lifted. Proceed as follows. 1. Carry out operation 27 120 10 or 27 120 20 Right or left--hand final drive casing, only removal (see Sect. 27, chapter 1). 2. Remove the cover (1). 4 3. Unscrew the lock nut (1).

5 4. Extract the braking assembly (1) recovering the disks and the brake support. 5. To refit the right or left--hand brake, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Insert the brake support and the braking assembly together with the disks.

Lock the assembly using the relevant nut, insert the cover

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

Op. 33 202 46 BRAKE HYDRAULIC PUMP Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 150 10 Cab with platform unit, only removal (see Sect. 90, Chapter 1). 2. Take off the cover with the logo from the steering wheel (1), using the tool 380000223 (2) detach the steering wheel (1).

3. Unscrew the retaining bolts and remove the black guard (1).

8 4. Unscrew all the retaining bolts and remove the grey guard (1). 5. Remove the relevant screws and detach the power shuttle control lever (5). 6. Remove the relevant screws, detach the electric connections and remove the control panel (2). 7. Mark and disconnect the connections of the ignition block (3). 8. Detach the rear guard (4) of the steering wheel.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

9. Disconnect the control pipes (1) from the service brake control pumps. 10. Disconnect the pipes (2) connecting the brake pumps to the brake fluid tank.

10 11. Disconnect the brake control pedals (1) from the pumps (2), unscrew the relevant fixing screws and detach the above parts.

11 12. Recover the brake pumps assembly, detach the connection pipe (1) to separate them. 13. To refit the brake control hydraulic pump unit, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Connect the two brake pumps using the connection piping.

Position the brake pumps and secure them, connect the relevant control pedals.

Connect the tank connection pipes and the brake control piping.

Position and secure the steering column rear guard.

Position and secure the steering block and connect the relevant electric connections.

Position and secure the control panel and connect the electric connections.

12 --

Position and secure the power shuttle control lever.

Position and secure the grey guard.

Position and secure the black guard.

Position and secure the steering wheel, insert the cover with the logo on the steering wheel.

Carry out operation 90 150 10 Cab with platform unit, only installation (see Sect. 90, chapter 1).

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

Op. 33 120 08 BRAKE CONTROL PEDALS Adjustments

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Check that the service brake pedal connection pin can be inserted in the right--hand pedal, if this is not the case then adjust the fork on the lowest pedal to align the pedal holes. 2. Check the height (A) of the service brake pedals from the floor that must be: A = 148 รท 152 mm for models equipped with cab; A = 158 รท 162 mm for models equipped with ROPS and noise deadening mat; A = 163 รท 167 mm for models equipped with ROPS. 3. Depress the brake pedals a few times to settle them in and check that the height is as prescribed. 4. Check that the brake pedals connection pin can be inserted without interfering with the right--hand pedal.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

Op. 33 202 04 BRAKE HYDRAULIC SYSTEM Air bleeding Air must be bled out whenever carrying out work on the brake hydraulic system. Proceed as follows. 1. Remove the cap and thoroughly clean the external parts of the assemblies near the bleeding screws and the hydraulic oil reservoir cover. 2. Check that the brake fluid reservoir (1) is full, both before and during bleeding.

3. Push the left--hand brake pedal down, slowly and fully, so that the oil is put in pressure. 4. Keep the pedal pressed down, unscrew the bleeding screw (1) by half a turn, allowing the oil/air bubble mixture to flow out. 5. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 6. Press the brake pedal again to put the circuit under pressure, i.e.: when the pedal travel returns to normal. 7. Repeat the aforementioned operation on the right--hand part of the brake circuit. 8. On completion of the operation, top up the oil level in the reservoir.

9. After having bled the rear brake circuit, thoroughly clean the external parts of the assemblies near the hydraulic oil reservoir cover (1). 10. Check that the brake reservoir (1) is full, both before and during bleeding.

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SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

12 Trailer brake valve

ATTENTION On tractors with a hydraulic trailer brake valve, after having bled the air from both the rear and front brakes, bleed the trailer brake valve by means of the screw (1).

27633

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Rear mechanical hydraulic lift INDEX Section

Description

Page

35 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Section views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

35 110 40

Lift internal controls. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

35 112 18

Draft sensing unit. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

35 110 10

Lift arms control shaft. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

35 112 10

Distributor assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 MAIN DATA

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

With separate position and draft control, mixed position/draft control function, draft sensitivity adjustment and float function

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lift--O--Matic device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

By means of two independent levers, external knob on the distributor

Response/lowering speed adjustment . . . . . . . . . . . . . . . . . . . . . Single--acting cylinder Rated bore and stroke . . . . . . . . . . . . . . . . . . . . . . Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulating valve setting . . . . . . . . . . . . . . . . . . . . Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . .

Enables fast lifting/lowering operations with the draft or position control levers By means of external knob on the distributor

mm cm3 bar bar

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90 x 117 750 190 ÷ 195 220 Three--point linkage I and II By means of top link

Lift capacity at ball ends . . . . . . . . . . . . . . . . . . . . . . . . . . . kg Lift capacity with centre of gravity at 610 mm from the ball ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

2192

Maximum stroke of lower arms . . . . . . . . . . . . . . . . . . . . . . mm With vertical tie--rods completely extended . . . . . . . . . . . . mm

636 520

1662

TORQUE SPECIFICATIONS Description

Thread

Torque Nm

Transmission gearbox/lift retaining bolts (C1) . . . . . . . . . . . . . . . . .

M10X1.25

67 ÷ 75

Transmission gearbox/lift retaining bolts (C1) . . . . . . . . . . . . . . . . .

M12X1.25

117 ÷ 129

Lift casing/distributor retaining bolts (C2) . . . . . . . . . . . . . . . . . . . .

M8x1.25

25 ÷ 30

Lift casing/hydraulic cylinder retaining bolts (C4) . . . . . . . . . . . . . .

M12X1.25

98 ÷ 127 (1)

Lift casing/hydraulic cylinder front retaining bolt (C4) . . . . . . . . . . .

68 ÷ 88 (1)

Three--point linkage support retaining bolts (C5) . . . . . . . . . . . . . .

M8x1.25

39 ÷ 49 (2)

(1) Apply Loctite 5699 -- (2) Apply Loctite 243.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TORQUE SPECIFICATIONS

C5 C4 C1

1 List of specific tools required for the various operations described in this section. X 9970873

Lift arms shaft seal drift.

X 9970874

Arm lift adjustment wrench.

X 9970877

Fitting for pressure check kit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

1 5

2 Hydraulic lift longitudinal section. 1. 2. 3. 4. 5.

Control valve Response speed adjustment valve Sensitivity adjustment valve Lift Arm Top link support (sensing unit)

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6. 7. 8.

Draft sensing rod Internal control linkages (to control position/draft/lift--o--matic) Lift casing

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC LIFT TROUBLESHOOTING Problems The lift has difficulty in supporting the load, there are rhythmic oscillations with the engine running, the load lowers with the engine switched off.

Possible causes

Solutions

1. Worn piston ring. 2. Exhaust valve not calibrated.

Replace seal. Adjust the sensitivity in the distributor or replace the valve. 3. Oil seepage from the safety val- Remove the distributor and adjust ve. or repair the valve. 4. Oil seepage from the check val- Remove the distributor and adjust ve. or repair the valve.

There are rhythmic oscillations 1. Incorrect adjustment of the le- Adjust the position control lever. with the arms lifted up to the ver of the position control that, rear limit switch device and the at the greatest lift height, cauengine running; with the ses the automatic operation of engine switched off the load the rear limit switch device. fails to lower. The draft control does not work, the lift raises and lowers only with the position control lever.

1. Incorrect adjustment of the Adjust the draft control lever. draft control lever.

The position control does not work, the lift raises and lowers only with the draft control lever.

1. Incorrect adjustment of the po- Adjust the position control lever. sition control lever. Overhaul the lift. 2. Internal linkages damaged.

The lift operates in jerks.

1. Low level of oil in the tank. 2. Pump inlet filter clogged. 3. Air in the pump suction line.

Top up oil. Clean or replace filter. Check the suction pipe, fittings and seal.

Lift not working.

1. Differential valve blocked or dirty.

Remove the distributor and free the regulator piston.

The lift fails to lower completely as far as the limit stop.

1. Incorrect adjustment of the position control lever (1).

Adjust the position control lever.

The lift fails to lower.

1. Exhaust valve blocked.

Remove the distributor and free or clean the exhaust valve.

The lifting capacity does not correspond to the specifications.

1. Deterioration in the distributor seal rings. 2. Relief and safety valves off setting. 3. Pump faulty. 4. Excessive seepage of oil from the distributor.

Remove the distributor and replace the outside seal rings. Check the calibration of the valves. Replace pump. Have the distributor overhauled.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC SYSTEM

DESCRIPTION AND OPERATION

This hydraulic system is the open centre type (in other words with continuous flow) and it is served by a hydraulic pump fitted directly on the distribution box, that uses the transmission lubrication oil. The hydraulic system described here mechanically senses changes in the draft loading via the third point (top link) of the three--point linkage. The system allows the operator to select Position Control, Draft Control, a combination of the two or float.

CAUTION

The hydraulic filter must be regularly replaced at the prescribed intervals. If the filter gets obstructed, there can be damage in the hydraulic system and in the transmission members. Always use genuine New Holland filters.

The system is controlled by the Draft Control lever (2) and the Position Control lever (1). Position control operation Position Control provides accurate control of implements, such as sprayers, rakes, rotary harrows, etc., that operate above the ground. Once set, Position Control will maintain the selected implement height. IMPORTANT: Always set the system to Position Control at any time when not actually operating in Draft Control, such as when attaching or transporting equipment or when no equipment is attached. Move the draft control lever (2) fully forward in the quadrant. Set the required implement height/depth using the Position Control lever (1). Pull the lever back to raise the implement, push forward to lower. Implement height/depth is relative to the position of the lever in the quadrant.

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An adjustable stop enables moving the lever back to the required work position. Draft control operation Move the position control lever (1) fully forward. Lower the tool into the work position using the draft control lever (2). Push the lever forward to increase the draft loading. Pull rearwards to reduce the draft loading. Forward movement of the draft control lever will increase implement depth and rearward movement will reduce the depth. Once set, the tractor hydraulic system will automatically adjust the implement depth to maintain an even pull on the tractor and so reduce wheel slip to a minimum.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Combined operation of position and draft control When working on ground that is very soft or of variable firmness, it can be necessary to use the combined functions of position and draft control. When starting work, lower the implement to the required depth by means of the Draft Control lever (2), as previously described. When the implement stabilises at the required depth, ease the Position Control lever (1) back until the lift arms tend to rise. The lift is now operating in Draft Control but the implement is prevented, by the Position Control function, from sinking too far when the draft load reduces.

Float operation Move the Position Control lever (1) and the Draft Control lever (2) fully forward. The 3--point linkage will now be free to â&#x20AC;&#x153;floatâ&#x20AC;? or follow the ground contour, a feature useful for scraper blades, etc.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

INTERNAL CONTROL LINKAGES A) Position control operation B) Draft control operation C) Combined position and draft control operation Position control operation Refer to figure 3. Positioning the draft control lever against the limit stop completely detaches the roller (11) that runs in the flywheel (7) of the draft control cam (12). In this position, the linkages of the draft control do not interfere with those of the position control. The arms are lifted by moving the position control lever (1) upwards and the control linkages will operate in the following manner: The articulation (4), integral with the shaft (3), turns clockwise and slides the roller (5) on the position control cam (6), as a result causing clockwise rotation of the flywheel (7). The flywheel transmits the rotary thrust in an anticlockwise direction, by

means of a friction strut (8), to the relay rod (9), that as a result moves the distributor shaft (21) into the delivery position), making the lift arms raise. During the arm raising stroke, the articulation (13) with the pin (10) turns anticlockwise and, operating on the lever (14), it makes the position control cam (6) turn anticlockwise. When the roller (5) comes into contact with the sloping face of the cam (6), it enables anticlockwise rotation of the flywheel (7) that, operating on the friction strut (8), rotates the lever (9) clockwise, loaded by the spring of the distributor control shaft (21), actuating the distributor in the neutral position (phase) and as a result blocking the movement of the lift arms. During the lowering phase, the movement of the above described levers takes place in the opposite direction. The position of the arms, during the phases of lifting and lowering, corresponds to that of the control lever (1).

14 5 4

6 13

11 3

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Draft control operation Refer to figure 3. By positioning the position control lever against the limit stop, the articulation (4) (fig. 3) moves into the position of maximum anticlockwise rotation. In this position, the roller (5) is fully lowered with respect to the sloping face of the position control cam (6), enabling anticlockwise rotation of the flywheel (7) and clockwise rotation of the relay rod (9), loaded by the spring of the shaft (21), that in its turn moves into the discharge position. In this position, the linkages of the position control do not interfere with those of the draft control. Refer to figure 4. Positioning the draft control lever (2) against the limit stop, makes the draft control shaft (16) rotate clockwise. The articulation (15), integral with the shaft (16), reaches the limit of clockwise rotation and, by means of the tie--rod (17), moves the roller (11), that in its turn operates on the draft control cam (12). This makes the flywheel (7) rotate clockwise that, operating on the friction strut (8), actuates the relay rod (9) anticlockwise, taking the distributor shaft (21) into the delivery position, consequently raising the arm. The arms stop only when the piston comes into contact with the pin of the limit stop (22). This limit stop, by means of the tie--rod (23), makes the lever (9) rotate clockwise, as a result compressing the spring of the friction strut (8) and thus freeing the shaft (21), that can therefore move into the neutral position, pushed by the respective spring. Moving the draft control lever towards the limit stop, the control linkage operates in the following manner:

The articulation (15), integral with the draft control shaft (16), turns anticlockwise and, by means of the tie--rod (17), slides the roller (11) on the flywheel (7). When the roller (11) comes into contact with the sloping face of the draft control cam (12), it enables anticlockwise rotation of the flywheel (7) that, operating on the friction strut (8), rotates the lever (9) clockwise, as a result leaving the distributor control shaft (21) free to move into the neutral position and, if you continue operating the lever, actuating the distributor onto the discharge position, as a result lowering the lift arms. During the initial movement of the draft control lever towards the limit stop, the function of lowering the arms is not actuated. The force of traction acting on the top link (20) actuates the tie--rod (18) making the flywheel (19) rotate clockwise together with the draft control cam (12), fastened to the same pin. When the roller (11) comes into contact with the sloping face of the draft control cam (12), it enables clockwise rotation of the flywheel (7) that, operating on the friction strut (8), rotates the relay rod (9) anticlockwise, as a result moving the distributor control shaft (21) into the neutral position, as a result stopping the lift arms. As the force of traction increases, the draft control cam (12) moves the roller (11) further, as a result increasing the previously described movement. The distributor control shaft (21) is moved from the neutral position into the delivery position raising the arms. As the force of traction decreases, the shaft (21) returns to the neutral position, or to the lowering position, with consequent operation of the control linkages in the opposite direction to the one previously described.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

20 19 18

7 15 4

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

(7), the roller (4) and the position control cam (6), the control shaft of the distributor (21) cannot pass onto the lowering position and as a result the arms cannot sink into the ground even if the force of traction acting on the top link (20) tends to decrease, negatively pressing on the tie--rod (18). This condition does not prevent the lift from working in draft control when, with more compact ground, the force of traction acting on the top link (20) tends to increase, positively pressing on the tie--rod (18). As a result, the combined position and draft control operation limits the height variations of the implement with respect to the ground, that occur when working in draft control, and at the same time it enables keeping the implement at the greatest set working depth.

Combined operation of position and draft control Refer to the figures 3 and. 4 To use the lift in these conditions it is necessary to observe the following instructions: â&#x20AC;˘ Move the position control lever upwards with respect to the limit stop until the greatest working depth is obtained. â&#x20AC;˘ Set the greatest desired working depth by means of the draft control lever, raising it from the zero position so that the roller (11), that actuates the draft control cam (12), moves the control shaft of the distributor (21) into the lifting position, making the lift arms raise further. Thanks to the position previously determined by means of the position control lever (1), the flywheel

20 19 18

7 15 5

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

OP. 35 110 40 LIFT INTERNAL CONTROLS D.A. (With the lift removed)

ATTENTION Handle all components with the greatest care. Do not insert hands or fingers between one part and another. Wear suitable protection clothing, including goggles, gloves and footwear.

Proceed as follows. 1. Unscrew the fixing screws and remove the external lift control lever assembly (1).

2. Unscrew the Allen screws (1).

7 3. Remove the cylinder (1) from the hydraulic lift casing.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

NOTE: Extract the seal (1) from the cylinder head.

9 4. Extract the piston (1) from the cylinder by pressing with a suitable aluminium bar from the front.

1 10 5. Take off the catches and remove the lever (1).

11 6. Remove the articulation (1).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

7. Remove the catch (1) from the pin of the compensator.

13 8. Unscrew the compensator pin until that the face of the pin comes out of the compensator.

14 9. Remove the articulations as shown in the figure.

15 10. Remove the articulation (1).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

11. Unscrew the clamping screws (1) and remove the position control cam (2) and the bracket (3).

2 17

12. Remove the pin (1).

18 13. Remove the cam (1).

19 14. Take off the catch (1) and remove the articulation (2).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

15. Unscrew the clamping screw (1) and remove the lever (2) together with the articulation (3).

Assembly

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

16. Go ahead and assemble the internal controls of the hydraulic lift proceeding in the opposite direction to disassembly.

Op. 35 112 18 DRAFT SENSING UNIT Disassembly -- Assembly

22 2. Take off the catch (1) and remove the parallel piece (2).

2 1 23

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

3. Unscrew the bolts (1) and the Allen screw.

24 4. Remove the pin as shown in the figure. 5. Remove the sensing unit from the lift casing.

25 6. Unscrew the Allen screws (1). 7. Remove the roller (2), springs (3), cover (4) and flange (5) from the draft sensing unit. 8. To fit the draft sensing unit, proceed as follows.

5 4 3

ATTENTION

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

1 26 ----

Reassembly follows the removal procedure in reverse, from step 7 back to step 1. Tighten all fasteners to the correct torques as detailed on page 3. The top surface of the spring roller: i) must be 1mm above the top surface of the flange ii) if at a lower distance, add shims, if at a higher distance, remove shims. Refer to the respective page for the correct adjustments. 27 84419869A - 06 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Op. 35 110 10 LIFT ARMS DRIVE SHAFT Disassembly -- Assembly

ATTENTION Handle all components with the greatest care. Do not insert hands or fingers between one part and another. Wear suitable protection clothing, including goggles, gloves and footwear.

Proceed as follows. 1. Remove the circlip (1) from the lift arms drive shaft.

1 28 IMPORTANT: Before removing them, use a punch (1) to mark the assembly positions of both lift arms and shafts to facilitate assembly in the original position. 2. Detach the lift arm from the shaft.

29 3. Repeat the operation on the other lift arm. 4. Remove the blocking sensor (1), blocking articulation and the shaft.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

5. Press the shaft from the left--hand side towards the right by lightly tapping with a mallet on an aluminium or copper bar. 6. To fit the arms drive shaft, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

31 -----

Reassembly follows the removal procedure in reverse, from step 6 back to step 1. Check the seals (1) and replace, if necessary. Use the special tool no. 9970873 to insert the seal. Tighten all fasteners to the correct torques as detailed on page 2.

1 32

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Op. 35 112 10 DISTRIBUTOR UNIT Removal -- Installation

ATTENTION Handle all components with the greatest care. Do not insert hands or fingers between one part and another. Wear suitable protection clothing, including goggles, gloves and footwear. 1. Unscrew the screws (1) and detach the distributor unit from the lift casing. NOTE: It is not possible to make any repairs on the distributor, it must be replaced if faulty. 2. Put the distributor unit back in position on the lift and tighten the screws (1).

33 IMPORTANT: Before installing them, check that the O--rings of the distributor (1) are not damaged, replacing them if necessary.

1 34

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 ADJUSTMENTS If completely dismantling the lift, it is necessary to make the following adjustments A) Adjust the position and draft control levers. B) Adjust the reaction spring C) Adjust the internal push rod A) Adjust the position and draft control levers. Refer to figure 35. This adjustment sets the position of greatest lift of the lift arms. Completely lower the arms and apply a light weight to them, sufficient to produce a pressure of 50--60 bar in the cylinder. Unscrew the fixing screws (6) so as to free the position control lever (1) from the shaft (5). With the draft control lever (2) completely lowered against the limit stop, lift the position control lever (1) against the limit stop.

Keeping the levers (1) and (2) stationary and with a 13 mm socket wrench, slowly rotate the position control shaft (5) anticlockwise so as to lift the arms up to the position of greatest height, determined by the internal hydraulic limit stop. Since, during the position control work, it is necessary to avoid activating the hydraulic limit stop, it is necessary to have a safety margin of tolerance in the order of 10 รท 15 mm. To this end, slowly rotate the shaft (5) clockwise as far as to lower the arms by this margin of tolerance with respect to the position of the lift limit stop. Now, keep the shaft (5) stationary and, with the lever (1) against the stop, secure the lever to the shaft, fully tightening the screw (6). To check the adjustment, completely lift the arms moving the position control lever (1) against the limit stop; completely lifting the draft control lever (2) there must be an additional upward movement of the lift arms. This movement must come within the distance of 15 รท 20 mm.

MMR0231A

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Connect the control levers Proceed as follows. Move the two levers (1 and 2) on the lift back to the limit stop. Move the lift control levers to the forward limit stop on the block. Adjust the horizontal tie--rods to make it possible to insert them onto the ball--end pins of the hydraulic lift control levers.

C) Adjusting the reaction spring Refer to the figure. 37 For the lift to function correctly, the bracket of the top link, when not working, must have no end float in the positive and negative directions of operation. If the parts have been fitted correctly, the spring carrier (2) should rest against the lift casing (1), and the cover of the spring carrier (4) against the flange (3). In this condition, the spring (M) is pre--loaded (compressed) by approximately 1.0 รท 1.2 mm.

36 Before fitting the whole reaction unit on the lift casing, pre--assemble the spring (M) so as to obtain a measurement of approximately 8.4 mm. On completing assembly of the reaction unit, make the definitive adjustment. Keeping the screw (V) stationary with an 8 mm wrench, adjust the self--locking nut (D), tightening or loosening it so as to eliminate the end float completely.

NEGATIVE TRAVEL

POSITIVE TRAVEL NEUTRAL 37

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 D) Adjusting the internal push rod Refer to the figure. 38 If it is necessary to dismantle the lift and replace the regulator (R), it is advised to measure the distance “X” (~10.5) so as to be able subsequently to reassemble the push rod in the same position. In addition, check that the measurement of the spring is 52 0/+0.3 mm. The distance between the push rod and the surface of the distributor is to be measured after making all the adjustments (draft sensitivity of the distributor, position control lever and draft control lever).

With the lift arms completely lowered and with no load or implements on the three--point hitch (neutral position), completely lower the two control levers (1) and (2) against the stops (F) (see the Fig. on page 14). In this position, press the push rod and, using an appropriate gauge, check that there is the correct distance of 112 0/+0.5. NOTE: If the distance “X” has changed, it will necessarily be necessary to repeat the adjustment of the position and draft control levers.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 2 -- Open centre system auxiliary control valves CONTENTS Operation

Description

Page

Main data -- Tools -- Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift -- Chap. 1 35 204 46

Auxiliary control valves D.A. (With unit removed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 SPECIFICATIONS

Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Auxiliary control valves Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Driving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

full--flow filter, with paper cartridge, (common to the hydraulic lift circuit) gear pump (common to the hydraulic lift circuit, see chapter 5) valve stack up to a maximum of 3 valves attached to the lift housing by hand lever 190 ÷ 195 (194 ÷ 199 kg/cm2)

Pressure relief valve setting . . . . . . . bar Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

convertible for operation of single or double--acting actuators, convertible for operation of single or double--acting actuators and with automatic detent release, convertible for operation of double--acting actuators with float control and automatic detent release, convertible for operation of double--acting actuators with float control.

List of specific tools required for the various operations described in this section.

380000240

Universal pressure testing kit.

380000241

Seal guard for Kontak control valve check valve.

TORQUE SPECIFICATIONS Parts to tighten

Thread

Torque Specifications

Control valve elements locknut

3/8” -- 24 UNF

Nm 20.4

kgm 2.1

Front and rear cover retaining bolts

1/4” -- 20 UNC

Nm 11

kgm 1

Auxiliary control valve retaining bolts

M 10 x 1.25

Nm 59

kgm 6

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

27 28 29 30 31 26

25723

A. B. C. D.

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

25 24

Auxiliary control valve cross--sectional views (fig. 1-- 2-- 3) Auxiliary control valve configured for operation of 12. Seal. a double--acting cylinder. 13. End cap. Auxiliary control valve configured for operation of 14. Control valve rod return spring. a single--acting cylinder. 15. Cover. Single/double--acting auxiliary control valve 16. Spacer. float and automatic detent release. 17. Tapered needle. Auxiliary control valve configured for operation 18. Spring. of a single/double--acting cylinder with 19. Seal. automatic detent release. 20. Coupling balls. Auxiliary control valve configured for operation 21. Seal. of a single/double--acting cylinder with 22. Seal. switching float control 23. Internal plunger. Single/double--acting operation switching valve. 24. Spring. Seal. 25. Cover. Valve retaining plug. 26. Detent release pressure adjuster screw. Seal. 27. Control valve rod return spring. Seal. 28. End cap. Non--return valve seat. 29. Seal. Non--return valve. 30. Detent notch body. Seal. 31. Ball support. Seal. 32. Seal. Control support. 33. Seal. Control valve rod.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

28 29 30 31 27 26

25 24

23 22

25724

E 25 24

25725

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

DESCRIPTION AND OPERATION

The auxiliary control valves serve for control of hydraulic loads external to the tractor.

Each control lever has three or four positions, depending on the type of control valve it operates.

1. Lifting -- Pull the lever towards the operator to extend the connected cylinder and lift the implement. Up to a maximum of 3 auxiliary control valves can be fitted, on the upper part of the lift housing.

2. Neutral -- Push the lever away from the operator, leaving the lifting position, in order to select the neutral position and deactivate the connected cylinder. The rear auxiliary control valves are operated by the levers to the right of the operator.

3. Lowering -- Push the lever further away from the operator, beyond the neutral position, to return the cylinder and lower the implement.

The levers and respective control valves are identified by colour as described below. 4. Float (only available on control valve II) Push the lever away from the operator, beyond the ”lowering” position to select the ”float” position. This will allow the cylinder to extend or return freely, permitting implements (such as blades) to follow the profile of the ground surface. Lever colour Green Blue Brown

Control valve position/No. RH external RH internal RH rear

--I --II --III

The hydraulic operation of these control valves is described on pages 6, 7 and 8.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR OPERATION OF A DOUBLE--ACTING CYLINDER (FIGS. 4 and 5 ) AND SINGLE--ACTING CYLINDER (FIGS. 6 and 7) 1. LIFTING -- On pulling back the control lever (located in the cab) the control valve stem (2, fig. 4) shifts to connect the cylinder bottom chamber with the delivery line (E) by way of the check valve (3) and line (G) and also the cylinder top chamber with the exhaust line (L) by way of line (H), intercepting the supply of oil to the hydraulic lift control valve. Keep the lever pilled back, to extend the cylinder to its full stroke. On releasing the lever it will automatically return to the neutral position under the action of the return spring, and the entire flow from the pump will be conveyed to the lift control valve by way of lines (M). 2. LOWERING -- To lower the implement, push the control lever (located in the cab). The control valve stem (2) will shift to the position indicated in fig. 5 thus allowing the oil in the lower cylinder chamber to flow to the exhaust (L) through the line (G), while the upper chamber is connected to the delivery line (E) through line (H) and check valve (3). 3. LIFTING -- On pulling back the control lever (located in the cab) the control valve stem (2, fig. 6) shifts to connect the cylinder with the delivery line (E) by way of the check valve (3) and line (G). Line (H), for the control of double--acting cylinders, is not used at this stage as it is permanently connected to the exhaust (L) by the open position of the switching valve (1). 4. LOWERING -- On pushing back the control lever (located in the cab) the stem (2) will shift to the position indicated in fig. 7. The oil contained in the cylinder, pressurised by the weight of the lifted implement, will flow to the exhaust (L) by way of line (G), while the entire flow from the pump is also conveyed to the exhaust (L) through the check valve (3) and line (H).

22123

M 4

22124

22125

pressurized oil Oil in suction, delivery or return

oil at static rest NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw. 22126

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT Pressurised oil Oil in suction, delivery or return

Oil at static rest

23 2

22127

M 8

LIFTING On pulling back the control lever (located in the cab), the control valve stem (2) shifts and the detent balls (26) engage the left hand groove, where they are held in place by the support (28) and spring (24). The movement of the spool (2) connects: delivery line (E) with the lower chamber of the cylinder, by way of the check valve (3) and the line (G), and also the upper cylinder chamber with the exhaust line (L) by way of line (H), intercepting the supply of oil to the hydraulic lift control valve. On completion of the lifting movement, the oil pressure increases to 170 รท

175 bar (173 รท 178 kg/cm2), acting through the port (V), it overcomes the resistance of the spring of the needle valve (23). Inside chamber (T) the oil pressure increases and, acting on the support (28), it overcomes the resistance of the spring, thus moving the support (28). In this condition the two detent balls (26) drop onto the support (28), releasing the stem (2) which, under the action of the spring (6), returns to the neutral position, and consequently the entire flow from the pump is conveyed to the lift control valve through lines (M).

22128

LOWERING To lower the implement, push forward the control lever (in the cab). The control valve stem(2) shifts and the detent balls (26) engage in the central groove where they are held in position by the support (28) and the spring (24). In this condition the oil contained in the lower chamber of the cylinder can flow to the

exhaust (L) by way of line (G), while the upper chamber is connected with the delivery (E) by way of line (H) and check valve (3). On completion of the lowering operation, the detent will be automatically released in the manner described previously.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/DOUBLE--ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT

Oil in suction, delivery or return

Oil at static rest

22129

M 10

FLOAT OPERATION For float operation push forward the control lever (in the cab). The stem (2) shifts and the balls (26) enter the right--hand groove, held in place by the support and spring (24). In this position the stem (2) connects: the two lines (M) providing the lift control valve with the entire pump flow and the two exhaust lines (L), by way of lines (H, G) respectively with the

upper and lower chambers of the cylinder. In this condition the only force exerted on the implement will be that created by its own weight, thus allowing the implement to follow the profile of the terrain and permitting the hydraulic lift to be used. Automatic detent release does not occur during float control as there is no pressure inside the auxiliary control valve.

Single/double--acting switching valve (of control valve fig. 8 -- 9 -- 10) 1. Single/double--acting switching valve. 2. Seal. 3. Valve retaining plug. 4. Seal.

NOTE: For operation of a double--acting cylinder, tighten the screw (1). For operation of a single--acting cylinder, loosen the screw. 25726

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

OP. 35 204 46 AUXILIARY CONTROL VALVES Disassembly--Assembly with the unit removed

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Convertible single/double acting auxiliary control valve Disassemble the auxiliary control valve into its component parts, referring to the cross--sectional views in fig. 1 and the following instructions. 1. Remove the cover (5), recover the spring (4) and the relative spring cup. 2. Extract the control valve stem (3). 3. Remove the control lever support (1) and recover the seal (2). 4. Remove the plug (6) and recover the single/double action switching valve (7). 5. Remove the valve housing (8) and recover the check valve and relative spring. 6. Check the condition of the seals before assembly. Single/double--acting auxiliary control valve float and automatic detent release

3 1

24452

Disassemble the auxiliary control valve into its component parts, referring to the cross--sectional views in fig. 1 and the following instructions: 1. Unscrew the retaining bolts, remove the cover (4) and the spacer (3). 2. Unscrew the retaining screws, recover the control lever support (1) and relative seal (2). 24453

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3. Extract the control valve stem (1). 4. Remove the cap (6, see fig. 12) and recover the single/double acting switching valve (7). 5. Remove the valve housing and recover the check valve and relative spring. 6. Check the condition of the seals before assembly. Diagram showing the installation of the tools and equipment required for the stem sticking test for control valves configured for double--acting operation (fig. 15) and control valves configured for single--acting operation (fig. 16).

24454

Control valve stem sticking test (figs. 15 and 16) NOTE: With the test equipment filled with HYDROSYSTEM 66 oil, the following tests must be performed at a temperature of approx. 60Â°C and with a flow rate of 12.5 litres/min, which can be obtained by running the electric motor at the fastest speed (1450 rpm). Install the auxiliary control valve assembly and the test equipment as indicated in the diagrams (figs. 15 and 16) and consider that:

on control valves configured for double--acting operation (fig. 15), the two cylinder delivery ports must be connected to the ball connector (3) by way of the pipes (2) and adjustable unions (1); -- on control valves configured for single--acting operation (fig. 16), the return line (2) must be connected, by way of the union (1), to the delivery port on the control valve (port located opposite to the switching valve). After having made the connections as indicated in the diagram, carry out the test as follows:

16 --

start the hydraulic pump and operate the hand lever to move the stem (in both directions for double--acting control valves); gradually increase the pressure by turning the handwheel on the test equipment, checking on the pressure gauge that the pressure reaches 172 bar (175 kg/cm2). In this condition the control valve spool should slide normally and return to the neutral position the moment the hand lever is released; repeat the test on the other control valves after making the appropriate connections.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Diagram showing the installation of the tools and equipment required for the control valve stem leakage test Valve leakage test Install the auxiliary control valve stack and the test equipment as indicated in the diagram (fig. 17) bearing in mind that the three--way union (1) must be secured on the single-- and double--acting control valves with suitable reducers. 17 After having made the connections indicated in the diagram, carry out the test as follows: --

start the hydraulic pump and gradually increase the pressure by turning the handwheel on the test equipment until a pressure of 147 bar (150 kg/cm2) is shown on the pressure gauge;

collect the leaked oil flowing from the union (2), in the burette provided (3) for a period of exactly one minute. Check that the quantity of oil collected does not exceed 25 cm3/ minute in the case of a new control valve, or 60 cm3/ minute for a used valve..

Repeat the test on each control valve, checking alternately the two supply lines to the related user cylinder.

ADJUSTMENT OF THE AUTOMATIC DETENT RELEASE PRESSURE Connect the control valve to the test equipment. Start the hydraulic pump and tighten the release pressure adjuster screw (26, fig. 1) until a pressure of 170 รท 175 bar (173 รท 178 kg/cm2) is obtained in front of the tapered needle (17). Lock the screw (26) in position by tightening the locknut.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 3 -- Trailer brake auxiliary control valve CONTENTS

Operation

Description

Page

Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

DESCRIPTION AND OPERATION The trailer brake valve, which has priority over both the auxiliary control valves and the hydraulic lift, is mounted on a support and secured on the front right--hand side of the engine, is controlled by the lift control pump. The hydraulic operation is described on pages 2 and 3.

The trailer brakes installed on ITALIA versions have the advantage that they brake the trailer even when the tractor engine is not running, and also when the pump is faulty or produces an inadequate oil flow. The description of the operation is given on pages 4, 5, 6, and 7.

Cross--sectional view of auxiliary control valve for trailer brakes. (Open--centre circuit). 1. 2. 3. 4. 5. 6.

Non--return valve Pilot valve body. Flow control valve Pilot valve piston. Pressure limiter. Piston

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

TRAILER BRAKES OFF -- With the trailer brakes off, the oil from the hydrostatic circuit connected to the control valve by union (Y) is not pressurised and therefore the piston (5) of the pilot valve (6) and the spool (7) are in the rest positions indicated in fig. 2.

The oil from the hydraulic pump arrives at the union (P1), passing through the diaphragm (1) and the pressure in the restriction (3) drops, thereby causing the flow control element (2) to shift to the right.

3 4

The majority of the oil flows through the union (N) to the auxiliary control valves, while the rest of the oil is discharged to the hydraulic lift through the line (4), the stem (7) and the union (R).

B 7

25259

Pressurised oil Oil in suction, delivery or return 2

Oil at static rest Tractor brake circuit oil at rest

Trailer brakes off. N. To auxiliary control valves. P1. From the hydraulic pump to the lift circuit.

Pressurised tractor brake circuit oil

R. To the lift return line. Y.

START OF BRAKING -- On operating the tractor brake pedals, the oil of the hydrostatic circuit in port (Y) is pressurised and thus shifts the piston (7) to the left, the pressure limiter (6) and the stem (8) which closes the passage between the oil return port (R), trailer brake port (B) and the line (5).

From the tractor brakes.

The oil inside the flow control valve (4) is maintained at a uniform pressure and so the valve element, under the action of the spring, shifts to the left to assume the position indicated in fig. 3.

The oil from the hydraulic pump in the union (P1) partly flows to the auxiliary control valves through the union (N) while the remainder flows to the trailer braking device via the diaphragm (2), line (3), check valve (1) and union (B).

As the pressure of the oil in the trailer brake port (B) increases, it acts on the active surface (9)of the spool (8), opposing the pressure applied on piston (7) by the oil in the hydrostatic tractor brake circuit.

4 5

25261

Y 3

Start of braking. B. To the trailer brake. N. To auxiliary control valves. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.

84419869A - 06 - 2011

From the tractor brakes.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3 BRAKING -- If the driver continues to operate the tractor brake pedals, the pressure of the oil in the trailer brake port (B) increases and acts on the active surface (10) of the spool (9), and overcomes the resistance of the springs (7) of the pressure limiter (8), to shift the spool to the right.

When the pressure in the trailer brake circuit balances the pressure exerted by the springs (7), the spool (9) stabilises in the position indicated in fig. 4 opening the passage connecting the oil from the pump with the hydraulic lift return line through port (P1), the diaphragm (2), restriction (5), line (6) and the port (R).

5 6

B 10

25260

4 The diaphragm (2) and the constriction (5) cause a drop in the pressure of the oil circulating in the flow control valve (4), thus shifting the valve element to the right to close passage (3) and consequently the check valve (1).

braking. B. To the trailer brake. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.

Further pressure on the tractor brake pedals shifts the piston (7, fig. 3), the pressure limiter(8) and the spool (2) to the left, thus causing an increase in the trailer brake circuit pressure, repeating the stages described in the paragraph START OF BRAKING.

From the tractor brakes.

Pressurised oil Oil in suction, delivery or return Oil at static rest

If the pressure in the trailer brake circuit increases as a result of external causes, the spool (9) shifts rapidly to open the passage connecting the trailer brake port (B) and the lift return port (R), thus maintaining a perfect balance between the oil pressure in the braking circuit and the force exerted by the springs (7) of the pressure limiter.

Pressurised tractor brake circuit oil

On releasing the tractor brake pedals, the pressure in port (Y) drops and the conditions illustrated in fig. 2 are restored.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4 21

5th 3

16 22 15

14 12 Oil in suction or delivery Discharge oil Tractor brake circuit oil at rest Oil at trailer brake release pressure

11 26430

8 9 10

5 ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running -- no action on brake pedals 1. Parking brake control lever -- 2. Relay -- parking brake warning light circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b Return solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer brake valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Delivery lines to auxiliary control valve and hydraulic lift -13. Service brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake line -- 16. Trailer brake ”ON” indicator switch -17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light. Oil from the hydraulic pump (9) arrives at the trailer brake valve (7), from where the majority is sent through line (12), to the auxiliary control valves and the hydraulic lift A small amount of oil reaches valve (6), where it is discharged in order to maintain the pressure at a level of 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2). Oil at a pressure of 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2) flows from the trailer brake valve through solenoid valve (5a), line (15) and coupling (14) to arrive at the trailer brake. This pressure level is required to overcome the resistance of the spring (19) and move the relative spring cap. At the same time, spring (17) shifts the piston (18) to prevent any braking action on the trailer.

Warning -- On starting the engine, in order to reduce the length of time required to bring the circuit up to the pressure required to release the trailer brake, with the parking brake lever lowered, operate the brake pedals (make sure that they are linked together). Once the trailer brake is released the warning light (22) will be switched off

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4 21

5th 3

19 5b

16 22 15

14 12

Oil in suction or delivery

25262

Discharge oil

Tractor braking circuit oil under pressure Oil at braking pressure 6

ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running -- brake pedals pressed Line connecting brake pump (13) to trailer brake valve (7) -- 1. Parking brake control lever -- 2. Relay -- parking brake warning light circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b Return solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer brake valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Delivery lines to auxiliary control valve and hydraulic lift -- 13. Service brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake line -- 16. Trailer brake ”ON” indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light. On operating the brake pedals, the pressure generated in line (A), closes the valve (6) return union (R) and consequently the pressure in the delivery line from the hydraulic pump (9) increases. The pressurised oil (12 ÷ 150 bar -- 12.2 ÷ 153 kg/cm2) flows out of the trailer brake valve (7) through line (B) to solenoid valve (5a), which is open, and through line (15) to the trailer brake, where it overcomes the resistance of the springs (17 and 19) to shift the pin (18) and thus brake the trailer.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4 21

5th 3

19 16

22 15

14 12

8 9

25263

Oil in suction or delivery

Discharge oil Tractor braking circuit oil brakes off 7

ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine either stopped or running but with insufficient flow from hydraulic pump 1. Parking brake control lever -- 2. Relay -- parking brake warning light circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b Return solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer brake valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -- 9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Delivery lines to auxiliary control valve and hydraulic lift -- 13. Service brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake line -- 16. Trailer brake ”ON” indicator switch -- 17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light. When the engine is stopped, or running but with insufficient flow from the hydraulic pump (9), the oil pressure at the trailer brake valve (7) is either too low or non--existent, and this condition causes the safety switch to close (8) The closure of switch (8) allows electrical current to energise relay (3), which closes the circuit to the solenoid valves (5a and 5b), thereby closing the former and opening the latter In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

4 21

5th 3

19 16

22 15

14 12

Oil in suction or delivery

8 9

25264

Discharge oil Tractor brake circuit oil at rest 8

ELECTRO--HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running -- with parking brake on 1. Parking brake control lever -- 2. Relay -- parking brake warning light circuit -- 3. Relay -- trailer brake circuit -- 4. Trailer braking control solenoid valves -- 5a. Delivery solenoid valve (normally open) -- 5b Return solenoid valve (normally closed) -- 6. Trailer brake release pressure control valve -- 7. Trailer brake valve (see pages 2 and 3) -- 8. Trailer brake circuit safety switch -9. Hydraulic pump -- 10. Filter -- 11. Brake control line -- 12. Delivery lines to auxiliary control valve and hydraulic lift -13. Service brakes pump -- 14. Tractor--trailer coupling -- 15. Trailer brake line -- 16. Trailer brake ”ON” indicator switch -17 and 19. Springs -- 18. Trailer brake control pin -- 20. Battery -- 21. Parking brake ”ON” indicator switch -- 22. Trailer brake ”ON” warning light. Parking brake (1) engagement makes the switch (21) close. This allows electrical current to energize relay (2), which closes the circuit to the solenoid valves (5a and 5b), thereby closing the former and opening the latter. In this condition, the oil in the trailer brake and line (15), under the action of spring (19), is discharged through solenoid valve (5b), and the braking action is obtained mechanically by the pressure of spring (19) on pin (18). The pressure drop caused by the oil discharging allows switch (16) to close and thereby allow current to reach and illuminate warning light (22) on the control panel

Warning -- After applying the parking brake, wait approximately 10 seconds before shutting off the engine, in order to allow all the oil to be discharged from the trailer brake cylinder and thus obtaining optimum braking.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

FUNCTIONAL TESTING AND TROUBLESHOOTING OF TRAILER BRAKE VALVE -- ITALIA VERSION 40o

50o

÷ C. Oil temperature Engine speed: 1000 rpm

Test conditions Electrical system powered. Parking brake disengaged. Trailer brake release pressure test

Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 kg/cm2 from kit 380000240. 2. With the engine and oil at the aforementioned conditions, the pressure should be 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2). 3. Check that the warning light (22, fig. 8) is not illuminated. 4. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).

25751

TROUBLESHOOTING Problems Possible causes Trailer brake release pressure = 1. Parking brake (1, fig. 8) on. 0 bar (warning light 22, fig. 8 ON). 2. Trailer brake release pressure control valve (6) incorrectly adjusted 3. Trailer brake circuit safety switch (8) faulty 4. Hydraulic pump (9) faulty

Solutions Disengage parking brake Renew it. Replace switch.

Overhaul or install a new hydraulic pump. 5. Delivery line solenoid valve (5a) Free or replace the solenoid valve locked in closed position 6. Discharge line solenoid valve Free or replace the solenoid valve (5b) locked in open position

Trailer brake release pressure 0 ÷ 1. Trailer brake release pressure Renew it. 11 bar (0 ÷ 11.2 kg/cm2). control valve (6) incorrectly adjusted Trailer brake release pressure correct, but warning light (22) illuminated

1. Trailer brake warning light Replace switch. switch (16) faulty

Trailer brake release pressure p i incorrect, but b warning i light li h (22) not illuminated

1. Warning light (22) bulb faulty

Change the lamp bulb

2. Trailer brake warning light Replace switch. switch (16) faulty

NOTE: The switch (8) can be identified by the red paint mark between the two terminals

84419869A - 06 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Testing the setting of the trailer brake system pressure control valve incorporated in the trailer brake control valve Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 250 kg/cm2 from kit 380000240. 2. With the engine and oil in the conditions described at the start of the chapter and applying a force of 30 ÷ 35 daN (29.4 ÷ 34.3 kg/cm2) on the service brake pedals, the pressure must be 135 ÷ 145 bar (138 ÷ 148 kg/cm2). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1). 25751

TROUBLESHOOTING Problems Pressure above or below prescribed range.

Possible causes

Solutions

1. Pressure control valve (6, fig. Replace trailer brake auxiliary 8) of trailer brake system faulty. control valve. 2. Hydraulic pump (9) faulty

Replace pump.

Testing the hydraulic system for leakage Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 250 kg/cm2 from kit 380000240. 2. With the engine and oil in the conditions described at the start of the chapter and applying a force of 30 ÷ 35 daN (29.4 ÷ 34.3 kg/cm2) on the service brake pedals, the pressure must be 135 ÷ 145 bar (138 ÷ 148 kg/cm2). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1). 25751

TROUBLESHOOTING Problems

Possible causes

On applying the prescribed force 1. Oil leaks in the hydraulic sysp , on the service brake pedals, tem. there h are an excessive i number b off 2. Excessive leakage from the pressure peaks over a 10--second solenoid valve (5b, fig. 8). period period. 3. Excessive leakage from trailer brake control valve (7).

Solutions Find and eliminate the leaks. Replace the solenoid valve. Replace trailer brake auxiliary control valve.

84419869A - 06 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 3

Checking that trailer brake release pressure is nullified when the parking brake is applied Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, pull the parking brake lever (1, fig. 8) fully upwards. 3. Check that the pressure is 0 bar and that warning light (22, fig. 8) is illuminated. 4. With the parking brake applied, disconnect the pressure gauge and union 380000550 (1). 25751

TROUBLESHOOTING Problems When the parking brake is applied the trailer brake release pressure is not nullified.

Possible causes Solutions 1. Parking brake switch (21, fig. 8) Replace switch. faulty. 2. Parking brake indicator relay Replace the relay. (2) faulty. 3. Discharge line solenoid valve Free or replace the solenoid valve (5b) locked in closed position or faulty.

Controlling the switches (8 and 16, fig. 8) Proceed as follows: 1. Insert union 380000550 (1) in the trailer brake coupling and connect to the pressure gauge with scale 0 ÷ 40 kg/cm2 from kit 380000240. 2. Without applying the service and parking brakes, operate the control lever of an auxiliary control (until the corresponding pressure relief valve is activated), hold this position for a few seconds then suddenly release the control lever. 3. Check that the parking brake release pressure remains at the prescribed level of: 11 ÷ 12 bar (11.2 ÷ 12.2 kg/cm2). 25751 4. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).

TROUBLESHOOTING Problems

Possible causes

On carrying out the operation 1. Trailer brake circuit safety described above, the trailer brake switch (8, fig. 8) setting higher release pressure is nullified than the nominal pressure (3 ± permanently. 0.5 bar). 2. Switches (8 and 16) installed in incorrect positions, or electrical leads connected incorrectly.

Solutions Replace switch.

Install the two switches in their correct positions or swap over the electrical power leads.

NOTE: The switch (8) can be identified by the red paint mark between the two terminals

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 8 -- Front Loader CONTENTS Section

Description

Page

General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Reference dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Parking the front loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal and installation of the various parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FRONT LOADER GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

655TL (NSL/MSL) kW

40 ÷ 58 (55 ÷ 80 HP)

Front tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11.2 x 24

Rear tyres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16.9 x 30

Bucket width: -.................................................... -....................................................

mm mm

1829 (72”) 2133 (84”)

Hydraulic cylinder dimensions: -Diameter of stem and diameter of lift control cylinder . . . . . . -Diameter of stem and diameter of bucket control cylinder . . .

mm mm

38 -- 80 38 -- 65

Maximum lifting capacity with bucket size 1829 mm (72”): -on the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -at 800 mm from the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

kg kg

1640 (NSL) -- 1540 (MSL) 1020 (NSL) -- 1055 (MSL)

Maximum lifting capacity with bucket size 2133 mm (84”): -on the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -at 800 mm from the pins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

kg kg

1630 (NSL) -- 1530 (MSL) 1010 (NSL) -- 1040 (MSL)

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure regulating valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . .

The same as the rear hydraulic lift bar

190 ÷ 195

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

C 1 Reference dimensions of the turret and of the quick coupler hook fasteners (dimensions in mm). A. Support bracket dimensions for NSL models. B. Support bracket dimensions for MSL models.

84419869A - 06 - 2011

C. Bucket support device hook fasteners.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

TORQUE SPECIFICATIONS Thread

Class

Thread

Class

8.8

10.9

8.8

10.9

M20

380

530

M8X1

M20X2

400

560

M10

M20X1.5

420

590

M10X1.25

M22

510

720

M12

110

M22X2

540

750

M12X1.5

118

M22X1.5

560

790

M12X1.25

123

M24

630

890

M14

130

180

M24X2

680

950

M14X1.5

138

190

M27

930

1310

M16

190

270

M27X2

995

1400

M16X1.5

210

290

M30

1260

1770

M18

270

380

M30X2

1370

1930

M18X2

280

400

M18X1.5

300

420

UNC

175

245

UNF

200

280

UNC

380

530

UNF

420

590

8” 5/ ” 8 3/ ” 4 3/ ” 4

STANDARD TIGHTENING TORQUES FOR HYDRAULIC PIPES AND FITTINGS Data for pipes and tapered fittings at 37° Dimension

∅ pipe

N⋅m

Thread

Tapered fittings at 37° with toroidal seal (O--ring) N⋅m

Min.

Max.

Min.

Max.

6.4

7/16--20

7.9

1/2--20

9.5

9/16--18

1.7

3/4--18

15.9

7/8--14

19.1

1--1/16--12

104

111

22.2

1--3/16--12

122

136

109

25.4

1--5/16--12

149

163

108

122

31.8

1--5/8--12

190

204

129

156

38.1

1--7/8--12

217

237

163

190

50.8

2--1/2--12

305

325

339

407

The above listed tightening torques apply to normal, cadmium--plated or galvanized screws whether lubricated or not.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

FRONT LOADER TROUBLESHOOTING Problems Small lift and tearout capacity.

Possible causes

Solutions

1. Low oil pressure in the circuit. Check the hydraulic circuit.

Loader and implement move 1. Insufficient quantity of oil in the Top up the oil level. slowly or not at all. hydraulic circuit. 2. Hydraulic couplings connec- Connect the hydraulic couplings corted incorrectly. rectly. 3. Multi Quick fast coupler failu- Check coupler and replace if necessre. ary. 4. Insufficient oil flow.

Check the hydraulic circuit.

Loader and/or implement move in 1. Incorrect connection of the Connect the quick couplers correctly. wrong direction relative to quick couplers. command given. Slow lift speed or no loader lift.

1. Insufficient quantity of oil in the Top up the oil level. hydraulic circuit. 2. Engine RPM too low.

Adjust engine speed.

3. Oil in the hydraulic circuit too Wait for the oil in the circuit to reach cold. the operating temperature. 4. Load above capacity.

Reduce load.

5. Hydraulic coupling trouble.

Check coupler and replace if necessary.

6. Hydraulic cylinder leakage.

Check cylinder and replace it if necessary.

7. Incorrect pressure relief valve Calibrate or replace pressure relief calibration. valve.

Lifted load lower than expected.

8. Hydraulic distributor trouble.

Check hydraulic distributor, replace if necessary.

1. Hydraulic cylinder leakage.

Check cylinder and replace it if necessary.

2. Load above capacity.

Reduce load.

3. Incorrect pressure relief valve Calibrate or replace pressure relief calibration. valve. 4. Hydraulic distributor trouble.

Check hydraulic distributor, replace if necessary. (continued)

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

FRONT LOADER TROUBLESHOOTING (overleaf)

Air in the hydraulic circuit 1. Hydraulic pump sucks air. (indicated by air bubbles in the oil).

Check that the unions are airtight and the seals and pipes are efficient.

The loader or implement do not 1. Hydraulic couplings not com- Connect the hydraulic couplings. complete the given travel. pletely connected. 2. Hydraulic coupling trouble.

Replace the faulty coupling.

Backward angle of the implement 1. Incorrect pressure relief valve Calibrate or replace pressure relief (only MSL models). calibration. valve. 2. The operator keeps the engi- Increase engine speed. ne speed too low.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

PARKING THE FRONT LOADER

NOTE: Ensure the ground is firm enough to support the loader. Proceed as follows. 1. Extract the cotter pin (1) and lower the stands (2) to make the blocking pin (4) enter the relevant housing hole, in this situation the stand will be in position (3).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 82 100 80 FRONT LOADER ARM CONNECTION BRACKETS Removal -- Installation

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground. 1. Unscrew the bolts (1) securing the pins. 2. Adequately support the bracket (3) and extract the connection pins (2), remove the bracket. Do this on both turrets. 3. To re--fit the bracket to the lift arm, proceed as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the bracket on the lift arm and insert the connection pins.

Tighten the retaining bolts to lock the unit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

CONTROL STRUTS Replacement (only MSL models)

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground. 1. Unscrew the relevant screws fastening the pins (1). 2. Detach the circlips (2), recover the spacers (3) (if applicable) and extract the pins (1). 3. Detach the control strut (4) from its seat. Carry out this operation on both struts. 4. To refit the control strut, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the control strut in its seat.

Insert the pins, position the spacers (if applicable) and secure them by means of the relevant circlips.

Tighten the bolts securing the pins.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

TRIANGULAR ARTICULATION LEVERS Replacement (only MSL models)

Proceed as follows.

NOTE: The lift arm must be fitted on the tractor and securely resting on the ground.

NOTE: Perform the following operation with engine switched off and hydraulic pipes detached. 1. Unscrew the relevant screws fastening the pins (1). 2. Detach the circlips (2), recover the spacer (3) and extract the pins (1). 3. Detach the two triangular articulation levers (4). Carry out this operation on both arms. 4. To refit the triangular articulation levers, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the two triangular articulation levers.

Insert the pins, position the spacers and secure them by means of the relevant circlips.

Tighten the bolts securing the pins.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 82 100 70 BUCKET SUPPORT DEVICE Removal -- Installation

Proceed as follows.

NOTE: The lift arm must be fitted on the tractor and securely resting on the ground.

NOTE: Perform the following operation with engine switched off and hydraulic pipes detached. 1. Unscrew the relevant retaining bolts and remove the pins (1). 2. Detach the bucket support device (2) from the lift arms (3). 3. To refit the bucket support device, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the bucket support device on the lift arms.

Lock the bucket support device by means of the pins and relevant screws.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 82 100 66 POSITION INDICATOR Disassembly -- Assembly

Proceed as follows.

NOTE: The lift arm must be fitted on the tractor and securely resting on the ground.

NOTE: Perform the following operation with engine switched off and hydraulic pipes detached. 1. Extract the cotter pin (2) and recover the spacers (3). 2. Detach the position indicator (1) from the relevant pin and extract it from the slide slot on the lift arm. 3. To refit the position indicator, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the position indicator in the slide slot on the lift arm and insert it on the relevant pin.

Position the spacers and secure them by means of the cotter pin.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 82 100 50 -- 82 100 57 BUSHINGS Replacement

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground. 1. Extract the pins from the lift arm (2) where the bushings are to be extracted. 2. Using an adequate drift extract the worn bushing (1). 3. Install the bushing on the lift arm, proceeding as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Install a bushing in its seat using an adequate drift.

NOTE: The installed bushing must be flush in its seat. --

Insert the pins removed previously.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

BUSHINGS Replacement (MSL models)

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground. 1. Detach the control strut (2) observing the instructions described on page 3. 2. Using an adequate drift extract the worn bushing (1). 3. Install the bushing on the control strut, proceeding as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Install a bushing in its seat using an adequate drift.

NOTE: The installed bushing must be flush in its seat. --

Install the control strut observing the instructions described on page 3.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 35 730 15 LOADER CYLINDER Removal -- Installation

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground.

NOTE: Pay great attention because the oil in the hydraulic circuit could maintain residual pressure. 1. Disconnect the lifting--lowering cylinder control pipes. 2. Unscrew the relevant retaining bolts and remove the pins (1) locking the cylinder (2). 3. Remove the loader cylinder (2). 4. Refit the loader cylinder, taking account of the following warnings.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the loader cylinder, insert the pins and secure them with the screws.

Before proceeding to start up the engine it is necessary to connect the control pipes.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

Op. 35 730 10 LOADER BUCKET CONTROL CYLINDER Removal -- Installation

Proceed as follows.

NOTE: The lift arm must be detached from the tractor and securely resting on the ground.

NOTE: Pay great attention because the oil in the hydraulic circuit could maintain residual pressure. 1. Disconnect the loader control piping. 2. Unscrew the relevant bolts fastening the pins (3), detach the circlips (1) and the spacers (2) (if applicable), finally extract the pins (3). 3. Remove the control cylinder (4). 4. To refit the loader bucket control cylinder, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the control cylinder, insert the relevant pins, spacers (if applicable), the circlips and tighten the screws fastening the pins.

Before proceeding to start up the engine it is necessary to connect the control pipes.

84419869A - 06 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 8

PINS Replacement

NOTE: The lift arm must be detached from the tractor and securely resting on the ground. 1. Unscrew the retaining bolts (2--3). 2. Detach the circlip (5), recover the spacer (1) (if applicable) and extract the pin (4) from its seat. 3. To re--fit the pin, proceed as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Apply the torque settings listed on page 3.

Position the pin in its seat, insert the spacer (if applicable) and the circlip.

Tighten the relevant retaining bolts.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

SECTION 41 -- STEERING Chapter 1 -- Steering CONTENTS Operation

Description

Page

Torque settings main data -- tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 41 204 10

Hydrostatic steering wheel. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

41 204 30

Hydrostatic steering control valve. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

41 204 34

Hydrostatic steering control valve removed. Disassembly -- Assembly . . . . . . . . . . . . . . 13

41 204 38

Hydrostatic steering control valve -- Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

41 216 10

Steering control cylinder. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

41 216 18

Steering control cylinder. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 .

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

SPECIFICATIONS POWER STEERING Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydrostatic control

Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

independent, fed by services hydraulic pump

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

paper cartridge on pump intake side

Control valve, manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OGNIBENE or DANFOSS

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

with the rotating valve controlled directly by the steering column; the steering continues to function even if the pump is damaged

Version code: Two and four wheel drive models (OGNIBENE) . . . . . . . . . . . . . .

STH ON 80 G170 LNV

Two and four wheel drive models (DANFOSS) . . . . . . . . . . . . . . .

OSPC 80 ON -- 150 N 1058

Pressure relief valve calibration (24, fig. 2) . . . . . . . . . . . . . . . . . . .

bar

165÷170 (168÷173.4 kg/cm2)

Cylinder safety valve calibration (33, fig. 2) . . . . . . . . . . . . . . . . . . .

bar

230÷240 (234÷244 kg/cm2)

TORQUE SPECIFICATIONS PARTS TO BE TIGHTENED

Thread

Bolt securing cover to power steering housing . . . . . . . . . . . . . . . . . . . .

Tightening torque Nm

kgm

M 8x1

24÷36

2.5÷3.7

Steering column flange retaining nut . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8x1

2.40

Bolt securing power steering to tractor . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10x1.5

4.5

Hydrostatic steering control pump retaining bolt . . . . . . . . . . . . . . . . . .

M 6x1

0.8

Nut for pump housing cover retaining bolt . . . . . . . . . . . . . . . . . . . . . . . .

M 10x1.25

Nut for securing thrust sleeve to pump drive shaft . . . . . . . . . . . . . . . . .

7/16”--20UNF --2B

2.8

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 TOOLS Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work safely and efficiently and obtain the best results, it is also necessary to use the recommended specific tools listed below and certain other tools, which are to be made according to the drawings included in this manual.

X 380000223 X 380000307 X 380000240 380000306 X 380000281 X 380000836

Steering wheel extractor. Power steering rotor retaining lever. Universal pressure testing kit. Plug for fitting the power steering rotating valve return springs. Tool for fitting power steering Rotoglyd seal. Tool for fitting power steering Varisel seal.

List of specific tools required for the various operations described in this section.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

OPERATION

Neutral position When the steering wheel (V, fig. 2) is not moving, the rotating valve (5) is located in the neutral position in relation to the sleeve (6). In this position, retained by springs (2, sect. A--A), the following occurs: -- the pin (1, sect. B--B) will be in the central position in relation to the holes on the valve (5); -- The lines (13 and 14) are aligned (sect. C--C) and therefore the oil, coming from the pump (P), flows freely to the outlet and returns into the tank; -- The grooves (15, 17 and 19) on valve ( sect. D--D, E--E) are not aligned with the ducts (16,18 and 20) on the sleeve, therefore all connecting lines with the cylinder remain closed (See diagrams A and d, fig. 2 and 3). Right--hand steering control B, R--ht, e, f,(see figure 2 and 3). By turning the steering wheel (V) clockwise, the springs (2, sect. A--A) allowing the valve (5) to rotate in relation to the sleeve (6), until the clearance G1 is recovered (sect. B--B). Under these conditions the following occurs: -- staggering of the lines (13 and 14, sect. C--C) and therefore break in the flow of oil to outlet; -- alignment of the six grooves (15, sect. D--D) with the same number of ducts (16), that are connected with the compartments on the rotor in the suction phase; -- alignment of the six delivery grooves (17, sect. E--E) with the ducts (18) communicating with the cylinder and simultaneously of the same grooves with the remaining ducts (16, sect. D--D), connected instant by instant with the compartments of the rotor in the delivery phase; -- alignment of the six discharge grooves (19) with the ducts (20, sect. E--E) in communication with the cylinder. Once the clearance (G1) has been recovered, the valve (5) rigidly transmits the steering wheel rotation to the sleeve (6) and rotor (9, fig. 2), by means of the internal pin and related shaft. The details (e, f, fig. 3), illustrate how the mechanism operates at the start of a turn to the right and after a certain number of steering wheel rotations. Note that there is an uninterrupted connection between the oil from the pump with the compartments on the rotor in the suction phase (and with oil when the compartments on the rotor are in the delivery phase) and the relative duct connected to the cylinder.

15714

1 Hydrostatic steering operation sectional view a. Cross--sectional views with the valve (5) in the neutral position -- b. Cross--sectional views with the valve (5) rotated for a right--hand turn (for a left--hand turn, the valve rotates symmetrically in the opposite direction) -- G1 and G2. Clearance between the pin (1) and the hole on the valve (5) --1. Sleeve trim pin (6) and shaft -- 2. Sleeve return spring (6) -- 5. Rotating valve -- 6. Valve seat sleeve (5) -- 13 and 14. Oil flow ducts in the neutral position -- 15. Delivery grooves (n.6) to the compartments on the rotor in the suction phase -- 16. Ducts (n.12) that are alternately connected to the grooves (15 and 17) -- 17. Delivery grooves (n.6) to the cylinder connected to the compartments on the rotor in the delivery phase and ducts (18 and 20) -- 18. Right--hand cylinder chamber delivery or discharge ducts (n.6) -- 19. Discharge grooves (n.6) cylinder connected to ducts (18 and 20) -- 20. Left--hand cylinder chamber delivery or discharge ducts (n.6) -- 22. Feed ducts for grooves (15).

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 M

S 14

5 13714

G Z

R D H

27 21

23 4

R-ht

17 33 34

B L-ht

13723

Delivery oil to control cylinder Delivery oil to rotor Intake oil, low pressure delivery or discharge Static oil

D M

El-ht

23 Er--ht 4

13722

2 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Left--hand steering control (B, L--ht, fig. 2) By turning the steering wheel in an anticlockwise direction, the movement of the parts is inverted, the delivery grooves (17, sect. E--E, fig. 1) direct the oil to the ducts (20), and control the left--hand turning action.

15 D-- D

F-- F

21 16

e 17

7884

Emergency hydraulic control (C, Er--ht, El--ht, fig. 2) In the event of feed faults, steering is still possible by turning the steering wheel. The valve (5) remains in the same position as with normal control and the rotor works in the same way as a hand pump, directing the oil to the control circuit. The non--return valve (4) opens and cuts off the feed pump, allowing the oil to flow directly from the reservoir to the rotor. The valve (23) remains closed in order to prevent oil leaks from faulty connecting pipes between the hydraulic pump and the power steering unit. Cylinder safety valve and backflow valve (see fig. 2) The safety valves (33), when open, discharge the pressure created by the piston (H) on one of the cylinder chambers as a result of the strong external stress on the wheels. At the same time, the lack of pressure in the opposite chamber is compensated by the flow of oil from the open backflow valve (34). Pressure on one of the cylinder chambers caused by weak external stress, insufficient to open the cylinder safety valve, is discharged by means of normal control valve leakage, whereas the lack of pressure in the opposite chamber is compensated by the backflow valve (34), as shown in fig. 2. This valve, as well as eliminating continuous steering corrections, prevents vibrations on front wheels (shimmy), hydraulic circuit failure and steering rod distortion.

Power steering operation circuit sectional views (*see fig. 1) A. Neutral position operation diagram. B. Right--hand turn (R--ht) and left--hand turn (L--ht) operation diagram. C. Emergency right--hand turn (Er--ht) and emergency left--hand turn (El--ht) operation diagram. d. Operation diagram for sections D--D and E--E in neutral conditions*. D. DANFOSS OSPC control valve. e,f. Operation diagrams for sections D--D and E--E in two successive right--hand turn phases*. F. Filter. H. Control cylinder. M. Pump delivery. N. Backflow valves (34) operation diagram with control valve (D) in neutral and cylinder (H) piston under external stress (indicated by the black arrow). P. Pump. R. Flow control. S. Discharge to gearbox. V. Steering wheel. Z. Resonance attenuator filter.

84419869A - 06 - 2011

4. Non--return valve. 5. Rotary valve. 6. Valve seat sleeve (5). 9. Rotor. 13 and 14. Oil flow ducts in the neutral position. 15. Delivery grooves (6) to the rotor compartments under suction. 16. Ducts (n.12) alternately connecting with the grooves (15 and 17). 17. Delivery grooves (n.6) to the cylinder connecting with the compartments on the rotor in the delivery phase and the ducts (18 and 20)*. 19. Discharge grooves (n.6) to the cylinder connecting with the ducts (18 and 20)*. 21. Ducts connecting the holes (16) with the compartments on the rotor in suction delivery phases. 23. Non--return valve. 24. Pressure relief valve (setting: page 2). 26. Left--hand cylinder chamber connecting duct. 27. Right--hand cylinder chamber connecting duct. 33. Cylinder safety valve (setting: page 2). 34. Backflow valve.

SECTION 41 -- STEERING -- CHAPTER 1

Hydrostatic steering control valve components 1. Dust ring. 2. Control valve body, rotary valve and rotary valve seat sleeve. 3. Check valve ball. 4. Seal. 5. Check valve threaded plug. 6. Thrust bearing components. 7. Retaining ring for springs (17) (Danfoss only). 8. Rotor drive shaft -- sleeve trim pin.

9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.

Rotor drive shaft. O--ring. Shim ring. Cover retaining screws. Washers. Cover. O--rings. Rotor and fixed ring for rotor. Springs for returning sleeve to neutral position. Pressure relief valve. Cylinder safety valve.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 HYDROSTATIC STEERING TROUBLESHOOTING

Problems Oil leaking from the hydrostatic steering unit: a. Control side. b. Cover side.

Possible causes Solutions 1. Rotoglyd seal (4, page 6) de- Replace the ROTOGLYD seal using the specific tool 380000281 or fective. 380000836 for VARISEL seal. 2. Bolts insufficiently tightened. 3.

Steering wheel excessively stiff.

1. 2. 3. 4. 5.

Excessive steering wheel play.

1. 2. 3. 4. 5.

The steering wheel turns normally, but the steering is: a. Slow. B. Null.

With the engine stopped, the steering wheel can be turned without turning the wheels.

2. 3.

Tighten the bolts to the prescribed torque (24รท36 Nm -- 2.5รท3.7 kgm). Sealing washers or O--rings Renew the washers and seals. defective. Hydraulic pump faulty. Repair the pump. Non--return valve held open Eliminate foreign bodies and clean by foreign bodies or due to ab- filter; place a new ball in the seat (if sence of ball. missing). Pressure relief valve (24) in- Calibrate the valve correctly. correctly set. Pressure relief valve jammed Eliminate foreign bodies and clean or held open by foreign bod- the filter. ies. Steering column has become Eliminate the causes. stiff on its bushing due to rusting, seizing, etc. Excessive play between the Replace the power steering control steering column and the cou- valve. pling with the rotating valve. Excessive play in the coupling Replace the power steering control between the shaft and the trim valve. pin. Excessive play in the splined Replace the power steering control coupling between the shaft valve. and the rotor. Combination of excessive Replace the power steering control play as described in the pre- valve. vious points. Leaf springs damaged or fa- Renew the springs. tigued. Inadequate control cylinder Replace seal. seal. Cylinder rod broken. Renew the damaged part. Rotor drive shaft or pin bro- Renew the damaged part. ken. Excessive wear between rotor Replace the power steering control and fixed ring. valve.

2. Non--return valve damaged.

Replace the power steering control valve. 3. Cylinder safety valve held Eliminate foreign bodies and clean open by foreign bodies or filter or replace the control valve. damaged. (continued)

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING TROUBLESHOOTING (overleaf)

Problems

Possible causes

Solutions

Steering wheel jolts, steering 1. Incorrect synchronisation of Synchronise correctly. uncontrollable, wheels steering in hydrostatic steering. Correct the connections. the opposite direction to the 2. Pipes to cylinder inverted. desired direction. The wheels do not maintain the desired alignment and continual correction with the steering wheel is necessary.

1. Hydraulic cylinder piston seal worn. 2. Cylinder safety or backflow valves held open by foreign bodies or damaged. 3. Mechanical wear of control valve.

Replace seal. Eliminate foreign bodies and clean filter or replace the control valve. Renew the control valve.

Neutral phase of power steering 1. Leaf springs, for sleeve return unobtainable. to neutral position, damaged or fatigued. During manual control, operation is normal; when stopping manual 2. Sleeve and rotating valve control the steering wheel tends locked in delivery position beto move on its own, or remain cause of the presence of forstationary, but steering continues eign bodies. slowly in the direction that was 3. Sleeve crushed on the rotating initially selected (motoring), valve due to excessive prestherefore steering must be sure. continually corrected with the steering wheel.

Replace the leaf springs assembly.

Vibrations on front wheels (shimmy).

Bleed the air and eliminate the causes of possible infiltration. Renew the worn parts.

1. Air pockets in the hydraulic cylinder. 2. Wear on mechanical joints on steering rods. 3. Cylinder safety or backflow valves held open by foreign bodies or damaged.

Difficulty in steering in general, or 1. Insufficient pressure. in one direction. 2. Excessive leakage inside the control valve. 3. Cylinder safety valve incorrectly calibrated or soiled with deposits that interfere with the seal of one of the two valves.

Eliminate foreign bodies and clean the filter.

Check the pressure relief valve calibration.

Eliminate foreign bodies and clean filter or replace the control valve. Check the hydraulic pump and the pressure relief valve calibration. Renew the control valve. Eliminate the foreign bodies and clean the filter or renew the control valve.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

10 Op. 41 204 10

HYDROSTATIC STEERING WHEEL (Replacement)

Removal

2. Using the tool 380000223 (2) detach the steering wheel (1).

Installation

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

Proceed as follows.

3. Position and secure the steering wheel to the related column.

4. Fit the cover with the NEW HOLLAND logo at the centre of the steering wheel.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Op. 41 204 30 HYDROSTATIC STEERING CONTROL VALVE Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 150 10 Cab with platform unit, only removal (see Sect. 90, chapter 1). 2. Take off the cover with the logo from the steering wheel (1), using the tool 380000223 (2) detach the steering wheel (1). 6 3. Unscrew the retaining bolts and remove the black guard (1).

7 4. Unscrew all the retaining bolts and remove the grey guard (1). 5. Remove the relevant screws and detach the power shuttle control lever (5). 6. Remove the relevant screws, detach the electric connections and remove the control panel (2). 7. Mark and disconnect the connections of the ignition block (3). 8. Detach the rear guard (4) of the steering wheel.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

9. Disconnect the piping (1) from the hydrostatic steering control valve.

9 10. Unscrew the screws (1) fixing the hydrostatic steering control valve to the steering column (2), recover the control valve from outside the cab. 11. To re--fit the hydrostatic steering control valve, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Position and secure the hydrostatic steering control valve to the steering column.

Connect the piping to the hydrostatic steering control valve.

Position and secure the steering column rear guard.

Position and secure the steering block and connect the relevant electric connections.

Position and secure the control panel and connect the electric connections.

Position and secure the power shuttle control lever.

Position and secure the grey guard.

Position and secure the black guard.

Position and secure the steering wheel, insert the cover with the logo on the steering wheel.

Carry out operation 90 150 10 Cab with platform unit, only installation (see Sect. 90, chapter 1).

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Op. 41 204 34 HYDROSTATIC STEERING CONTROL VALVE R.I. (with control valve removed) To disassemble the power steering control valve, proceed as follows: 1. Remove the cover retaining bolts.

24701

11 2. Remove the cover by sliding to the side.

24702

12 3. Remove the rotor fixed ring, the rotor and the inner spacer.

4. Remove the two O--rings on the rotor fixed ring.

24703

13 5. Extract the rotor drive shaft.

24704

14 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

6. Extract the thrust washer.

24705

15 7. Remove the threaded plug on the non--return valve seat.

24706

16 8. Extract the O--ring seal from the control valve body.

24707

17 9. Rotate the control valve body and extract the non--return valve ball, the two balls with the relative pins and the backflow valve springs.

27856

18 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

10. Position the control valve body and the rotor drive shaft so that the sleeve--control shaft trim pin is in a horizontal position.

11. Push the rotary valve inwards, so that the valve, the valve seat sleeve and the thrust bearing can be extracted from the control valve body. 24709

19 12. Extract the thrust bearing from the rotating valve, complete with the two external rings, and remove the spring retaining ring from the valve seat sleeve.

24710

20 13. Extract the valve--sleeve trim pin.

24711

21 Warning -- On assembly, two reference marks were made on the rotating valve and the sleeve, corresponding to the neutral position maintained by the springs. Before removing the springs, check that the marks are clearly visible, otherwise renew them.

24712

22 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

14. Extract the rotary valve from the valve seat sleeve.

24713

23 15. Remove the springs from the neutral position, extracting them from their seats.

24714

24 16. Remove the dust seal and the O--ring seal from their seats in the control valve body.

20428

25 17. Using a 6 mm Allen wrench, remove the threaded plugs from the cylinder safety valves.

20429

26 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

18. Remove the seal washers.

27857

27 19. Using a 6 mm Allen wrench, remove the calibration adjuster screws on the cylinder safety valves.

27858

28 20. Turn the control valve body over, extract the springs and the balls from the two cylinder safety valves.

20432

29 Cylinder safety valves components (order of disassembly--assembly). 1. Cylinder safety valve ball. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Shut--off plug.

25790

30 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

21. Using a 6 mm Allen wrench, remove the threaded plug on the pressure relief valve and extract the washer.

20434

31 22. Remove the pressure relief valve adjuster screw.

27859

32 23. Turn the control valve body over and complete disassembly by extracting the spring and the pressure relief valve piston.

20436

33 Pressure relief valve components disassembly--assembly). 1. Pressure relief valve. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Shut--off plug.

(order

27099

34 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

24. Thoroughly clean all control valve component parts. 25. Replace the washers and seals. 26. Carefully check all mechanical parts, replacing components that show signs of wear. 27. Before refitting, lubricate the components with hydraulic oil.

28. Re--fit the rotating valve on the sleeve, checking that the reference marks indicated in the drawing coincide.

24712

35 29. Use tool 380000306 to insert the flat and curved springs (12, fig. 3). Diagram for fitting springs (12, fig. 3 neutral position).

24728

36 30. After inserting the springs in the seat, align and centre them as shown in the figure.

24729

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

31. Fit the neutral position spring retaining ring on the valve seat sleeve, remembering that the ring must rotate freely without being impeded by the springs.

24730

38 32. Insert the sleeve--rotor drive shaft trim pin.

24731

39 33. Fit the thrust bearing, following the order and indications shown in the drawing below.

24732

40 1. Bearing external ring. 2. Thrust bearing. 3. Bearing internal ring with bevel facing the shim on part. (5). 4. Rotary valve. 5. Rotary valve seat sleeve.

1 2 3 4 5 24733

41 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

34. Position the control valve body so that the housing seat on the rotating valve sleeve is positioned horizontally.

35. For the ROTOGLYD seal (OGNIBENE hydrostatic steering) insert the guide bushing (1) of tool 380000281 in the rotary valve seat.

24734

1 42

36. Lubricate the ROTOGLYD seal (1) with hydraulic fluid and position it on the head of tool 380000281 with the flat portion of the ring facing in front of the tool.

24735A

43 37. Insert tool 380000281 in the guide bushing positioned beforehand. 38. Whilst holding the external bushing with the hands, press fully down and simultaneously rotate the tool 380000281 in order to facilitate the entry of the ROTOGLYD seal in the control valve body seat. 39. Extract the parts on tool 380000281 (external bushing and punch); NOTE: the support and seal ring support head remains on the control valve body. 24736

44 40. For the VARISEL seal (DANFOSS hydrostatic steering) grease the seal (3) and insert it on the outer edge of the guide bushing (1) of tool 380000836.

27824

45 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

41. Position the tool 380000836 complete with components (1) and (2) and the VARISEL seal (3) on the power steering control valve body (4). 42. Press fully down, whilst simultaneously rotating the outer bushing (1) on the tool, in order to facilitate the entry of the VARISEL seal (3) in the control valve body seat. 43. Using the bushing (1), press on the shaft (2), in the direction indicated by the arrow, in order to overcome the pressure exerted by the inner spring. Extract the tool from the body of the power steering when the tapered portion of the shaft (2) comes free from the seal (3)

27825

46 44. Insert the parts that were previously fitted in operations 26รท31, on the control valve body, holding the sleeve--rotor drive shaft trim pin in a horizontal position, to prevent it from slipping out and jamming in the slots inside the control valve body.

24739

47 45. Press the rotary valve taking the thrust bearing into contact with the control valve body; with this operation, at the same time, we eject the head (1) of the tool 380000281.

27826

48 46. Rotate the control valve body and insert the non--return valve ball into the seat indicated by the arrow.

24741

49 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

47. Screw the threaded plug into the non--return valve seat until the upper surface is below the coupling surface of the control valve body.

24742

50 48. Insert the non--return valve balls into the two seats indicated by the arrows.

27861

51 49. Insert the springs on the backflow valve pins.

27862

52 50. Position the pins, complete with springs, in the backflow valve seats.

27863

53 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

51. Lubricate the O--ring seal and insert into the seat on the control valve body.

24746

54 52. Fit the thrust washer, so that the holes coincide with the holes on the control valve body.

24748

55 53. Make a reference mark on the upper part of the teeth (1), in line with the seat (2), to indicate the exact position of the valve--to--sleeve trim pin.

24748

56 54. Fit the rotor drive shaft into the control valve body, insert tool 380000307 for retaining and centring the rotor drive shaft, between the rotor drive shaft and the thrust washer, rotating the shaft so as to facilitate coupling between the seat (2, fig. 56) and the trim pin installed on the sleeve.

24749

57 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 55. To re--fit the rotor, proceed as follows: a) each time the hydrostatic steering is disassembled, turn the rotor over so as to limit wear to the splined coupling; b) in the drawing below, the rotor shaft has been removed in order to show the phasing between the rotor, rotor drive shaft and the trim pin; c) fit the rotor on the drive shaft, remembering that correct timing is obtained by aligning the teeth (1), on the trim pin axis plane (shown in drawing 59) with the centre line of one compartment on the rotor.

24750

58 56. Lubricate the two O--ring seals (1) with hydraulic oil and insert them in the rotor fixed ring seat, fix in position by aligning the retaining holes (2) with those present on the thrust washer.

24751

59 57. Fit the cover, aligning the retaining holes with those on the rotor fixed ring.

24753

60 58. Remove retaining tool 380000307 and fit the special screw and washer in the non--return valve seat, shown in the drawing.

24754

61 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

59. Fit the other six cover retaining bolts with the washers and tighten in diagonal sequence to the torque setting value shown in the table on page 2.

24755

62 60. Turn over the control valve body and insert (see component details in fig. 34) the pressure relief valve piston in the seat indicated in the figure.

24756

63 61. Insert the pressure relief valve spring.

24757

64 62. Using an 8 mm Allen wrench, insert the pressure relief valve calibration screw. NOTE: calibration will be carried out on the workbench or on the tractor to the values shown in the table on page 2.

24758

65 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 63. Tighten the plug (2) with the relative seal, using an 8 mm Allen wrench, and tighten to the prescribed torque value of 40รท60 Nm (4.1รท6.1 kgm), after having carried out the calibration operation on the workbench or on the machine. 64. Insert the two balls (1) into the cylinder safety valve seats, indicated by the arrows (see component details in fig. 70).

1 2

25789

66 65. Insert the springs (2, fig. 70) in the cylinder safety valve seats.

27865

67 66. Using a 6 mm Allen wrench, tighten the two cylinder safety valve calibration adjuster bolts (3, fig. 70). Note -- Calibration will be carried out on the workbench or on the tractor to the values shown in the table on page 2.

20475

68 67. Tighten the two plugs (5, fig. 70) and the relative seals (4) using a 6 mm Allen wrench. Once calibration is completed, tighten to the prescribed torque value of 30 Nm (3 kgm).

20429

69 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Cylinder safety valves components (order of disassembly--assembly). 1. Cylinder safety valve ball. 2. Pressure spring. 3. Calibration adjuster screw. 4. Seal. 5. Shut--off plug.

25790

70 68. When the unit has been assembled, insert the dust seal in the seat in the control valve body.

24764

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1 OP. 41 204 38 HYDROSTATIC STEERING CONTROL VALVE

Bench tests A -- CHECKING ROTATING VALVE WEAR 1. Make the connections shown in fig. 76 and complete the circuit as in fig. 72. Using the splined drive shaft (1, fig. 73) hold the power steering control valve in the steering position (right or left). 2. Using the handwheel (5), increase the circuit pressure to approach the pressure relief valve setting (page 2) without it tripping. 3. Apply a torque wrench (2) to the drive shaft (1) and tighten to a setting of approx. 34 Nm (3.5 kgm), check that the rotating valve takes more than ten seconds to complete one full rotation. If less than ten seconds, replace the complete control valve. Test Conditions. Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51 Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W Oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . 60_C Hydraulic pump capacity . . . . . . . . . . . . . . dm3/min . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (litres/min) 12 Electric motor speed . . . . . . . . . . . . . . . . . 1450 rpm

7 6

5 3

24911

4 72

1. Splined control shaft -- 2. Plug G 1/2” -- 3. To the restriction -- 4. Exhaust -- 5. Three--way coupling G 1/2” -- 6. From delivery line -7. Discharge coupling G 1/2”.

5 4 24912

Installation diagram of equipment for testing the rotating valve, seals and for pressure relief valve calibration. 1. Splined control shaft. 4. Restriction. 2. Torque wrench. 5. Pressure adjustment handwheel. 3. Delivery.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

B -- CHECKING RETURN TO NEUTRAL POSITION In the same test conditions as A, check that the rotating valve automatically returns to the neutral position when the drive shaft (1, fig. 73) is released after each simulated steering movement. C -- SEAL CHECK In the same test conditions as A, hold the rotating valve in the steering position with the drive shaft (1) for approx. three minutes and check the seals for leaks. D -- PRESSURE RELIEF VALVE CALIBRATION 1. Make the connections as shown in the diagram in the figure ( 73) and complete the circuit as in the drawing ( 72). 2. Using the drive shaft (1, fig. 73) simulate a turn (to the left or to the right) so as to interrupt the oil flow to the discharge. 3. Gradually increase the pressure in the circuit by turning the handwheel (5) fig. 68, and check on the pressure gauge that the pressure relief valve (24, fig. 3) cuts in at the pressure shown on page 2. If not, increase or reduce the pressure relief valve setting by tightening or slackening the adjuster screw.

E -- CYLINDER SAFETY VALVE CALIBRATION For steering to the left 1. Make the connections as shown in the diagram in fig. 73, and complete the circuit as in the figure 74. 2. Using the drive shaft (1, fig. 73), simulate a turn to the left (anticlockwise rotation) so as to interrupt the oil flow to the discharge. 3. Gradually increase the pressure in the circuit by turning the handwheel (5), and check on the pressure gauge that the pressure relief valve (26, fig. 3), is activated at the pressure shown on page 2. If the pressure differs from the prescribed value, increase or reduce the valve setting (26, fig. 3), by tightening or slackening the adjuster screw. For steering to the right Make the connections as shown in the diagram fig. 73 and complete the circuit as in fig. 75. Proceed in the same manner as described above, by simply reversing the direction of rotation of the drive shaft (1).

1 1

2 2

25800

3 25799

75 74

Cylinder safety valve calibration for steering to the left 1. From delivery line -- 2. To the restriction -- 3. Exhaust. 84419869A - 06 - 2011

Cylinder safety valve calibration for steering to the right 1. From delivery line -- 2. To the restriction -- 3. Exhaust.

SECTION 41 -- STEERING -- CHAPTER 1

CHECKING THE HYDROSTATIC STEERING PRESSURE RELIEF VALVE WITH CONTROL VALVE INSTALLED ON TRACTOR Proceed as follows:

1. Start the engine and perform a few steering movements with the tractor, until the oil reaches a temperature of approx. 50o C.

2. Switch off the engine and detach the oil delivery pipe union (1) on the hydraulic cylinder (2).

27151

76 1. 2. 3.

3. Replace the original union with unions (4 and 3), and connect the pressure gauge (5) with a scale of 0รท150 kg/cm2 from kit 380000240.

4. 5.

Hydraulic cylinder oil delivery pipes. Hydraulic cylinder. Union 380000613 (supplied with kit 380000240) to be connected to the pressure gauge (5). Union 380000618 (supplied in kit 380000240) to be fitted in the place of the original union. Pressure gauge supplied with kit 380000240.

4. Start the engine again, bring the speed up to medium rpm, and apply full--steering lock to bring the hydraulic cylinder to the stroke--end position.

In this condition the pressure relief valve (24, fig. 3) should intervene, with the pressure gauge showing the value prescribed on page 2.

5. If the pressure value is slightly different, the valve can be calibrated (24, fig. 3) by means of the adjuster screw.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Op. 41 216 10 STEERING CONTROL CYLINDER Removal -- Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

NOTE: The steering control cylinder can be removed from either the complete tractor or with the front axle removed. Its removal from the tractor with the front axle removed is described here. Proceed as follows. 1. Unscrew the ball joints (1) and remove them from the shaft (2) (on both sides).

2. Disconnect the steering cylinder control pipes (1 and 3) and unscrew the union (2).

78 3. Unscrew the ring nut (1) fastening the steering control cylinder to the front axle.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

4. Levering with a crowbar between the union (1) and the axle body, extract the steering control cylinder (2). 5. To fit the steering control cylinder, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Position the steering control cylinder in its seat on the front axle.

Screw on the union and the cylinder control pipes.

Screw on the ring nut fastening the cylinder to the axle.

Screw the ball joints onto the cylinder shaft.

Check the leading wheel geometry (see sect. 25, Chap. 1, page 32).

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

Op. 41 216 18 STEERING CONTROL CYLINDER Disassembly -- Assembly

82 3. Remove the collet (1).

83 4. Extract the shaft (2) with the seal holder ring (1).

84 84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

5. Check the seals removed beforehand and also the ones on the cylinder (1); replace them if deteriorated. 6. To fit the steering control cylinder, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Lubricate all components.

Insert the shaft with the seal holder ring onto the cylinder.

Lock the seal holder ring with the stop ring.

Fit the fastening circlip.

84419869A - 06 - 2011

SECTION 41 -- STEERING -- CHAPTER 1

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

SECTION 50 -- CAB AIR CONDITIONING SYSTEM Chapter 1 -- Cab air conditioning system CONTENTS Operation

Description

Page

Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Use of the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools and general characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Operating principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Main components of the cab air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cab controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 50 200 03

Operation control and cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Refrigerant recovery -- recycling and evacuation -- charging stations . . . . . . . . . . . . . . . . 22

50 200 04

Filter/dryer, recharging and cooling control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

50 200 06

Checking for fluid/gas leaks in the air conditioning system . . . . . . . . . . . . . . . . . . . . . . . . . 31

50 206 51

Cab heating/air conditioning system R.I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

50 206 66

Cab electric fan unit Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

50 200 72

Air--conditioning system condenser. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 36

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

CAB AIR CONDITIONING SYSTEM

CAUTION

freezing caused by coolant can be treated by gradually unfreezing the injured zone with cold water and then applying a grease based cream. Request medical assistance.

the air conditioning system contains a mixture of refrigerant and oil under high pressure; under no circumstances loosen pipe fittings/unions or work on the pipes without having first evacuated the system.

for the same reason, never unscrew the compressor oil level plug when the system is charged.

do not heat the refrigerant container. If the temperature exceeds 50Â°C the pressure will increase very rapidly.

keep the air conditioning system away from heat sources to prevent explosions as a result of an increase in pressure in the system.

The refrigerant must be handled with great care in order to avoid personal injury: always use safety goggles and gloves. Avoid contact with skin and eyes. Liquid refrigerant can cause freezing of the skin and serious damage to the eyes, sometimes resulting in permanent blindness. Keep the refrigerant container away from heat sources. Heat will cause an increase in pressure of the refrigerant and could cause the container to explode. If refrigerant comes into contact with a naked flame or a hot metal surface it produces a toxic gas. If inhaled, this gas can cause serious poisoning. To avoid the possibility of accidents take the simple precautions described below. The operation of emptying and charging the system must be carried out in a well--ventilated area, well away from any naked flames. During the charging and emptying operations, take the necessary precautions to protect the face and above all the eyes from accidental contact with refrigerant. If an accident should occur, proceed as follows:

if refrigerant splashes into the eyes, wash immediately with a few drops of mineral oil, then wash them thoroughly with a solution of boric acid and water (one spoonful of acid in 1/4 cup of water) and seek medical assistance immediately.

84419869A - 11 - 2007

When transferring refrigerant from one container to another, only use homologated liquid refrigerant containers equipped with safety valves.

Never fill liquid refrigerant containers over 80% of their maximum capacity.

Do not modify the settings of safety valves and the control devices.

Never connect the recovery/recycling and evacuation/charging stations to electrical power outlets with voltages other than those specified; do not leave the stations powered up unless they are to be used immediately.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

USE OF THE AIR CONDITIONING SYSTEM

Warning -- The air conditioning system will not function when the engine is not running, as the engine drives the compressor.

The air conditioning system provides dehumidified air or warm dehumidified air.

cool,

To operate the system, proceed as follows.

ADJUSTMENT

To obtain correct cab air conditioning, when the system is in operation keep the recirculation vents open, whilst keeping the doors and front and rear windows closed.

For maximum cooling, the knob (3, fig. 13) must be turned fully to the left in an anticlockwise direction.

STARTING

Starting the system at low temperatures can damage the compressor. Only operate the air conditioner when the engine is hot and the temperature inside the cab is at least 20 °C.

Warning -- Before starting the engine, make sure that the air conditioning push button (2, fig. 13) is in the ”off” position.

Warning -- Before switching on the conditioner, always switch on the electric fan. When the fan is switched off the air conditioning will not function.

NOTE: In order to increase the pressure inside the cab, and prevent foreign bodies entering when working in extremely dusty conditions, it is advised to keep the recirculation vents closed.

The air--conditioner dehumidifying function operates at all temperatures and can be set by rotating the knob (3, fig. 13).

In order to create optimum temperature conditions, after prolonged idle periods in hot sunshine, it is advised to start the tractor moving, switch on the air conditioning and open the rear window for approximately one minute, to discharge the heated air in the cab.

With the engine running and the electric fan on, press push button (2, fig. 13) to start the air conditioner. STOPPING After a few minutes of operation, the liquid visible in the sight glass at the top of the filter (3, fig. 2) should be clear and free of bubbles. If not, contact the specialised personnel at your dealer.

Before stopping the engine, always switch off the air conditioner by pressing push button (2, fig. 13), then turn the fan control knob (1) to the ”off” position.

84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 TOOLS REQUIRED FOR SERVICING THE CAB AIR CONDITIONING SYSTEM

Warning -- The operations described in this section can only be carried out with ESSENTIAL tools indicated by an (X). To work in safety and to obtain the best possible results whilst saving both time and energy, we recommend that the other specific tools in the list are also used.

List of specific tools required for the various operations described in this Section X 380000315 380000314 X 380000312

Recovery, evacuation and charging station Acoustic gas leak detector Combs for cleaning and straightening the fins on the condenser and evaporator

CAB AIR CONDITIONING SYSTEM CHARACTERISTICS SANDEN SD 7H15 Compressor Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cm3

155

Maximum rotation speed . . . . . rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6000

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

6.5

Quantity of lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3

185

Type of lubricating oil (code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAG SP10

Air conditioning system

Gas HRC134a

Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . g

1300

System delivery side pressure . . . . . . . . . . . . . . . . . . . bar

(kg/cm2)

10 ÷ 22 (10.2 ÷ 22.4)

System suction side pressure . . . . . . . . . . . . . . . . . . . . bar

(kg/cm2)

0.2 ÷ 2.5 (0.2 ÷ 2.5)

Pressure switch setting (high pressure) . . . . . . . . . . . . bar

(kg/cm2)

25 (25.5)

Pressure switch setting (low pressure) . . . . . . . . . . . . bar (kg/cm2)

2 (2)

Temperature of refrigerant fluid at compressor outlet . . . . . . . . . oC

60 ÷ 120

Temperature of refrigerant fluid at condenser outlet . . . . . . . . . .

40 ÷ 60

Temperature of refrigerant fluid at evaporator outlet . . . . . . . . . .

0 ÷ 15

Maximum capacity of electric centrifugal fan I, II, III speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/min

84419869A - 11 - 2007

3.0 ÷ 6.5

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 OPERATING PRINCIPLES The function of the air conditioning system is to create and maintain optimum working conditions inside the tractor cab. The climate inside the cab essentially depends on four factors: --

temperature;

humidity;

speed;

purity of the air in the cab.

Obviously ”ideal” conditions will vary from person to person, and so it is not possible to specify optimum values for the above factors; however, we can specify a range of values within which the majority of people will feel most comfortable. As regards temperature and humidity, we can define a zone, known as the ’comfort zone’, within which the temperature and humidity combination corresponds to satisfactory climatic conditions. From the diagram it can be seen that humidity should be within the range of 30% to 70%. Below 30% there is excessive dehydration of the mucous tissue of the nose and throat, whereas above 70% an uncomfortable sense of dampness may be perceived. The temperature may therefore vary between 18 and 28°C. The speed of the air flow must not be so great as to cause discomfort; speeds of 0.07 -- 0.25 m/s are normally acceptable.

As regards air purity, no precise limits have been defined; however, it is important to remember that the human organism gradually alters the composition of the air in the surrounding environment by breathing, increasing the amount of carbon dioxide and humidity, and decreasing the amount of oxygen, etc. These problems can be eliminated by allowing a small flow of external air to enter the cab. However, as agricultural tractors are often used in dusty conditions (dust from the earth, hay, etc.), the installation of dry filters on the external air inlets provides a simple solution. The use of air conditioning in tractors and agricultural machinery in general serves to neutralise unpleasant climatic conditions inside the cab; the air conditioning system controls the temperature and humidity of the air drawn into and already present in the cab so as to maintain a comfortable climate for the operator. The operating principle of the system is similar to that of a domestic refrigerator: heat is removed from the air by means of a physical process (the evaporation of a liquid) which draws heat from the surrounding environment. The liquid used in this process (refrigerant) is a product with a high refrigeration coefficient, low toxicity and mixes well with lubricating oils. The various components of the system are connected by pipes in which the refrigerant circulates. Relative humidity %

Simplified psychometric diagram 1. Sensation of unbearable coldness. 2. Sensation of coldness. 3. Comfort zone. 4. Sensation of heat. 5. Sensation of unbearable heat.

25372

Temperature oC

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

MAIN COMPONENTS OF THE CAB AIR CONDITIONING SYSTEM The air conditioning system comprises five main components: 1. Compressor; 2. Condenser; 3. Dryer filter; 4. Thermostatic expansion valve; 5. Evaporator. To understand the operating cycle of the system, follow the flow of the refrigerant starting from the compressor (1). The compressor draws in vaporised refrigerant at a pressure of 0.2 ÷ 2.5 bar compressing it to a pressure of 10 ÷ 22 bar. The refrigerant, heated by compression to 60÷120 °C, is directed to the condenser coil (2) (still in vapour form) located in front of the engine radiator. The air flow, produced by the electric fan and the forward movement of the tractor, cools the refrigerant by means of heat exchange. This action cools the refrigerant to the point of condensation between 40÷60 °C depending on the outside temperature, changing the vapour into liquid.

The refrigerant, in liquid state at high pressure, is purified by passing through the filter/dryer (3) from where it flows to the expansion valve (4), which restricts the flow of refrigerant and thus reduces its pressure. As it passes through the expansion valve (4), part of the refrigerant is transformed into vapour and the low temperature mixture of vapour and liquid thus formed enters the evaporator (5). Here the electric fan causes a continuous circulation of the cab air over the fins of the evaporator (5), helping the refrigerant to absorb heat from the air and thus change completely from a liquid to vapour. The evaporation process removes heat from the air passing over the evaporator (5) and thus reduces the temperature inside the cab. The flow of air over the cold surface of the evaporator (5) also condenses some of the moisture in the air and therefore reduces the humidity in the cab. On leaving the evaporator (5) at 0÷15 °C the low pressure mixture is taken in by the compressor (1) to start a new cycle.

25372

2 Schematic diagram of the air conditioning system 1. 2. 3.

Compressor. Condenser. Dryer filter.

84419869A - 11 - 2007

4. 5.

Expansion valve with thermostatic sensor. Evaporator.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Compressor

The compressor serves to pressurise the refrigerant and force it through the system.

SANDEN SD 5H11 MODEL

Axial reciprocating piston type, driven by the engine crankshaft via a vee belt. 25375

The operation of the compressor can be summarised as follows: The swashplate (4), on which pivot the ball ends of the connecting rods of the pistons (2), rests on the cam rotor (5). As the cam rotor rotates it exerts a continuous thrust on the swashplate, which is prevented from rotating by the coupling with the fixed gear (3). The angle of the swashplate causes reciprocating movement of the pistons.

the

The reed valve (1) on the cylinder head with five lobes (one for each piston) controls the inlet and discharge stages of the cylinders. The valve opening and closing system is automatic, achieved by preloading of the shutter blades. The rotating parts of the compressor are lubricated by special oil, inserted during assembly, some of which circulates through the system mixed with the refrigerant.

COMPRESSOR OIL -- TYPE AND QUANTITY

3 Axial flow reciprocating piston compressor SANDEN SD 5H11 1. 2. 3. 4. 5.

Combined inlet and discharge valve. Piston with seal ring. Driving gear. Connecting rod disk. Cam rotor.

Also remember that:

Never leave the compressor oil container open, always make sure that it is tightly closed. If left exposed the oil will absorb humidity from the air and may, subsequently, damage the system. Do not transfer compressor oil from the original container to another container. Do not introduce any additives to the compressor oil. Any additional substances could contain elements which are incompatible with the chemical base of the refrigerant and thus alter its characteristics. Do not use engine oil of any type to lubricate the compressor and the system.

The tractor is equipped with a SANDEN SD 5H11 compressor for R134a refrigerant. After assembly, the compressor is filled with 185 cm3 of PAG SP10 lubricating oil. In case of top up or oil change, use only this type of oil. It is not necessary to check the compressor oil level unless the system develops significant gas leaks.

Warning -- If the system develops significant leaks of R134a refrigerant, there will also be a significant loss of PAG SP10 compressor oil. It will therefore be necessary to check the compressor oil level, remembering that of the total quantity of lubricating oil (185 cm3) on average only 130 รท 135 cm3 will be present in the compressor, whilst the remainder (50--55 cm3) will be in circulation through the various system components. For problems of this type, we recommend that you seek assistance from an authorised NEW HOLLAND service centre.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Condenser

The condenser (1) is the system component in which the refrigerant vapour condenses to form a liquid.

The condenser works in similar way to the engine cooling radiator, allowing the vapour to give up heat to the external air.

It comprises a series of inner tubes through the refrigerant flows and a outer shell consisting of a series of thin aluminium fins which increase the surface area in contact with the cooling air flowing through the condenser.

The condenser radiator is fitted under the engine bonnet, in front of the engine radiator. This is the ideal position to take full advantage of the air flow from the radiator cooling fan, necessary for heat exchange.

Dryer filter The filter/dryer (1) is fitted under the engine bonnet, positioned between the condenser and the expansion valve, performs two basic functions, acting as a filter to remove solid and liquid particles from the refrigerant and as a temporary storage container during variable charge stages.

It is important to eliminate water from the system to prevent corrosion and consequent damage to the components. 5 The filter therefore contains substances capable of absorbing humidity.

Solid particles, such as grit, metal particles produced by the mechanical wear of the compressor, oxides, etc., can also damage the system and so the filter incorporates screens to retain them.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Thermostatic expansion valve

This valve serves to reduce the pressure of the liquid refrigerant from the condenser so that the refrigerant entering the evaporator can evaporate and thus take heat from the air which is to be cooled.

4 7

The expansion valve has two main functions:

25389

the calibrated bore (6, fig. 6) inside the valve body creates a difference in the pressure of the refrigerant between the inlet (4) (liquid state) and the outlet (7) (mixed liquid/vapour state); the calibrated bore (6) also serves to atomise the refrigerant to facilitate subsequent evaporation;

modulation: inside the valve body a thermostatic sensor controls the valve aperture so that the right quantity of refrigerant enters the evaporator to ensure complete evaporation.

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

Expansion valve block. From the evaporator outlet. Thermostatic sensor. To compressor suction inlet. From filter/dryer. Spring Calibrated bore and ball. To evaporator inlet.

NOTE: In the event of malfunction, replace the valve.

If the thermostatic sensor (2, fig. 6) detects an increase in the temperature of the refrigerant at the evaporator outlet, the flow of refrigerant is increased.

If the temperature in the cab drops or the compressor starts to operate at a higher capacity (due to an increase in engine speed), the flow rate into the evaporator is reduced.

The expansion valve is installed on the evaporator inlet fitting (7), and as the internal refrigerant flow control system is completely automatic, it requires no special maintenance.

To perform functional testing, with the system is fully charged, check that the system operating pressures are those indicated on page 4.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Evaporator

Thermostatic switch (ANTI--FROST)

The cooling cycle is completed inside the evaporator. The refrigerant at the expansion valve outlet is a mixture of vapour liquid at low temperature and low pressure. As it passes through the evaporator it absorbs heat from the cab air, evaporates, and is then taken in by the compressor. The operation of the evaporator is controlled by the expansion valve which regulates the flow of refrigerant to obtain the required degree of air cooling. The evaporator performs the opposite function to the condenser, but it is constructed in a similar way, the only differences being the overall dimensions and the internal pipe layout. The evaporator also has dehumidification of the cab.

another

function:

The air passing over the evaporator contains a certain quantity of moisture, and this must be kept within certain limits for operator comfort. Some of the humidity in the air condenses on the fins of the evaporator. The centrifugal fan draws the ambient air through the fins of the evaporator (where it is cooled and dehumidified) and into the cab. The housing around the evaporator is equipped with a condensate trap from which the condensate is carried outside the vehicle through discharge tubes.

7 The thermostatic switch (thermostat) is a safety device, fitted with a sensor (1, fig. 7) inserted on the evaporator outlet pipes (2), where it constantly monitors the temperature. The sensor bulb is filled with a special gas which expands or contracts according to the temperature, acting on a membrane connected to a complex mechanism which opens or closes an electric circuit connected to the compressor electro--magnetic clutch, switching the compressor on or off as required. The thermostatic sensor (1) therefore prevents ice from forming on the evaporator, as a result of the treatment of extremely damp air, and obstructing the flow of air into the cab. For this reason, in the event of replacement or maintenance operations, it is important that the thermostatic sensor (1) is inserted on the evaporator outlet pipes (2). Tape the two components together with insulating tape in order to ensure efficient system operation.

NOTE: In the event of malfunction, replace the thermostatic switch (1).

84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

CAB HEATING AND VENTILATION CONTROLS VENTILATION Turn on the cab ventilation by means of the selector switch (2, fig. 8) and direct the air flow by positioning the front vents (3, fig. 9). The air can be drawn in from the outside and from the inside of the cab through the side air recirculation vents (fig. 10). Fresh air drawn into the cab from outside is always filtered. When the electric fan is operating and with the doors, re--circulation vents and windows closed, the pressure inside the cab is higher than the pressure outside, and consequently air can only enter the cab via the side filters.

Electric fan The fan control switch (2, fig. 8) is powered up when the ignition switch (2, fig. 12) is in position B. The electric fan has four operating speeds. Air filter

DANGER Remember that the filters of the cab provide no protection against anti--parasitic chemicals in general. Protection against these products can only be obtained by taking the specific precautions required for each individual product. This applies to all types of filter, for which the prescriptions for use and maintenance must be followed scrupulously. Even the use of active carbon filters does not exempt the operator from adopting the personal safety precautions recommended for the product in question.

84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

12 HEATING

The heating control knob (1, fig. 11) allows the operator to regulate the air temperature, by increasing or decreasing the coolant circulation from the engine. The electric fan control switch (2) allows the operator to regulate the quantity of air entering the cab through the vents.

Temperature control knob (1)

Turned fully to the left in an anticlockwise direction = minimum temperature (hot water circulation off).

Turned fully to the right in a clockwise direction = maximum temperature (hot water circulation fully open).

NOTE: The total capacity of the cooling system is 14 litres for models without a cab and 16 litres for models with a cab.

STARTER SWITCH

To operate the three functions on the switch (2, fig. 12) turn the key to the following positions: A. No power supply to any of the circuits (key can be removed). Engine stopped: automatic activation of fuel injection cut--off. B. Standby for engine start up. Operation of panel lights and instruments. Power supplied to various circuits. 12 C. Engine start--up: when released, the key returns automatically to position (B).

84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

CAB AIR CONDITIONING CONTROLS AND TEMPERATURE CONTROL

Electric fan speed control and air conditioning button. The system operates with the ignition key switched on. Turn the knob (1) to turn on the air--conditioner. Turn the knob (1) to select the four fan speeds. The indicator light (3) comes on to signal the air conditioner has started up. Heater control knob For maximum temperature, turn the knob (2) clockwise (fully to the right). To shut off the water supply to the heater and switch off the heater, turn the knob (2) fully counter--clockwise.

NOTE: To pressurise the cab, see the Ventilation chapter on page 11 in this Section.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

OP. 50 200 03 FUNCTION AND COOLING TESTING With the pressure gauges connected to the system in the manner described on page 22 and the cocks closed, proceed as follows: 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Check that the knob (2) is turned fully to the left (maximum cold), so as to exclude the heating function. 3. Set the cab ventilation fan (1) to maximum speed. 4. Turn the knob (1) to turn on the air--conditioner.

After the system has been in operation for about 15 minutes, check the following values: 5. Pressure on the suction side of the compressor, as indicated by the low pressure gauge. 6. Pressure on the delivery side of the compressor, as indicated by the high pressure gauge. 7. Ambient air temperature. 8. Ambient relative humidity. 9. Temperature of air leaving vents inside the cab. The pressure values will depend on the external ambient conditions and the altitude. The system is to be considered as functioning correctly if the pressure and temperature readings are within the value ranges indicated on the table below.

14 Gas HRC134a

Air conditioning system Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . g

1300

(kg/cm2)

10 ÷ 22 (10.2 ÷ 22.4)

System suction side pressure bar . . . . . . . . . . . . . . . . . bar (kg/cm2)

0.2 ÷ 2.5 (0.2 ÷ 2.5)

Pressure switch setting (high pressure) . . . . . . . . . . . . bar (kg/cm2)

25 (25.5)

Pressure switch setting (low pressure) . . . . . . . . . . . . bar (kg/cm2)

2 (2)

Temperature of refrigerant fluid at compressor outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oC

60 ÷ 120

Temperature of refrigerant fluid at condenser outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oC

40 ÷ 60

Temperature of refrigerant fluid at evaporator outlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . oC

0 ÷ 15

Maximum capacity of electric centrifugal fan I, II, III speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/min

3.0 ÷ 6.5

System delivery side pressure . . . . . . . . . . . . . . . . . . . bar

PRESSURE VARIATIONS AT DIFFERENT ALTITUDES 84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Altitude (m) above sea level

Absolute atmospheric pressure (kg/cm2)

Correction (kg/cm2)

1.029

300

0.994

-- 0.035

600

0.959

-- 0.070

900

0.924

-- 0.105

1200

0.889

-- 0.140

1500

0.854

-- 0.175

1800

0.819

-- 0.210

2100

0.791

-- 0.238

2400

0.763

-- 0.268

It should be remembered that altitude affects pressure, as indicated in the table above. In order to obtain the pressure value in the various sections of the system, the relative correction value must be subtracted from the pressure gauge reading.

Checking the temperature of the air coming out of the vents inside the cab

If the temperature of the air measured at the vents inside the cab is within the value range indicated in the following table for the external ambient air temperatures specified, the system is functioning efficiently.

If the temperature of the air at the vents exceeds the maximum value indicated in the table, refer to the FAULT DIAGNOSIS GUIDE, on the following pages.

CAB VENTS TEMPERATURE TABLE

External ambient temperature

20°C

Air temperature at vent outlets (inside cab)

27°C

4 ÷ 8°C

28°C

35°C

6 ÷ 12°C

36°C

43°C

12 ÷ 20°C

10. Carry out temperature checks on the high and low pressure parts of the system:

11. The compressor should not be excessively noisy, there should be an audible click when the drive is engaged.

all high pressure parts -- from the compressor delivery fitting to the condenser, expansion valve installed on the evaporator unit -- should be uniformly hot to touch.

all low pressure parts, -- from the expansion valve outlet to the suction fitting on compressor -- should be uniformly cold to touch. There should not be excessive condensation on the suction pipe and the low pressure pipe connector on the compressor.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

MAINTENANCE OF THE CAB AIR CONDITIONING SYSTEM

1) COMPRESSOR: check the mountings, the tension of the drive belt and the oil level.

At the start of the season in which it will be used, check the efficiency and operation of the system. If the system has been out of use and charged for a prolonged period, oil may have flowed out of the compressor to other parts of the system and consequently this oil must be returned to the compressor. To carry out this operation, proceed as follows 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Check that the knob (2, fig. 14) is turned fully to the left, in order to turn off the heating function and provide maximum cooling. 3. Set the cab ventilation fan (1) to maximum speed. 4. Turn the knob (1) to turn on the air--conditioner. After the system has been in operation for about 15 minutes, check the following values: Check that the relative temperatures of the external ambient air and the air flowing out of the vents inside the cab correspond to the values indicated in the table on page15. If the temperature values are correct, the system is perfectly efficient and only requires a visual inspection of the main components.

2) CONDENSER: check mounting and that the fins are free of excessive deposits. Straighten any bent fins using the comb tool 380000312.

NOTE: Carry out the same checks on the EVAPORATOR (9) and the CONDENSER (5). 3) FILTER/DRYER: the sight glass on the receiver--drier can provide useful information about system operation, as described below. Replace the receiver--dryer after the system has been repaired on two occasions. 4) EXPANSION VALVE: this valve does not require maintenance; in the event of malfunction contact specialised personnel of the NEW HOLLAND service network. If the value of the air temperature at the vent outlets is not in compliance with the data given in the table on page 15, search for the causes of the drawbacks that can have produced the inefficiency of the installation, as described below.

25374

15 1. 2. 3. 4. 5. 6.

Compressor. Inlet pipe (low pressure). Outlet pipe (high pressure). Warm air. Condenser. Air drier filter.

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Schematic diagram of the air conditioning system. 7. Sight glass. 8. Expansion valve with thermostatic sensor. 9. Evaporator. 10. Cool, dehumidified air.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Also remember that: When disconnecting the hoses, close the ends with plastic caps to prevent foreign matter and humidity from getting inside the hoses. Handle the thermostatic sensor carefully during removal operations to avoid damage. Always use two spanners to unscrew the hose fittings to avoid twisting the fitting.

25380

16 The sight glass on the receiver--drier can provide useful information about system operation. The 4 possible conditions of the sight glass are shown in the figure 16. A. Transparent glass This could indicate that the system is correctly charged, or that there is no refrigerant in the system (in the latter of these cases the cooling action of the evaporator would be absent). In other cases the system might have been charged with an excessive quantity of refrigerant (in this case the system pressure must be checked. B. Bubbles in the glass The formation of vapour or foam bubbles indicates that the system contains an insufficient quantity of refrigerant or the presence of air in the system. Bubbles may also be occasionally seen on switching on the system and on disengagement of the electro--magnetic clutch. C. Threads of oil in glass Indicates a lack of refrigerant and that the compressor oil is circulating in the system. D. Non--uniform (streaky) fluid in glass Indicates that the drying agent in the filter has leaked into the circulating system (as a result of the containment disks breaking).

WARNINGS FOR AIR CONDITIONING SYSTEM REPAIR OPERATIONS Warning -- If any of the system components need to be replaced, follow the safety instructions noted in Section 50 and always follow the recovery, recycling and charging operations described in op. 50 200 04.

AIR CONDITIONING SYSTEM FAULT DIAGNOSIS SUMMARY There are three main ways in which the system can malfunction: -- the system does not work at all; -- the system does not provide sufficient cooling; -- the compressor operates irregularly. Bearing in mind that insufficient cooling may also result from causes external to the air conditioning system, generally a mechanical check and visual inspection will provide useful information about the efficiency of the system. This information can then be supplemented by electrical testing. If the cause of the problem has still not been identified, it will be necessary to carry out a more thorough investigation and test the pressure in the various sections of the system, as specified previously. Visual inspection of components All visual inspection should be carried out with the engine stopped and the cab heating and air conditioning system switched off. -- Check that the cab external air intakes are clean. -- Look for visible leaks of liquid refrigerant on hoses or system fittings. -- Check that the engine, condenser and evaporator radiators are clean. -- Check that the thermostatic sensor makes contact with the evaporator outlet hoses, using the special thermal tape, to ensure efficient system operation. Follow the troubleshooting operations described on the following pages.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 AIR CONDITIONING SYSTEM TROUBLESHOOTING THE SYSTEM DOES NOT WORK

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Check fuses.

Check compressor drive belt tension.

Check if the clutch coil is receiving power.

Check that the ground contact is efficient

Check the system control devices -- the relays, wiring, thermostat, etc.

Visually check the condition of all fittings, unions and pipes.

Check the clearance between the front disk and pulley of the electro--magnetic clutch.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) COOLING INSUFFICIENT

HIGH DISCHARGE PRESSURE AND/OR HIGH SUCTION PRESSURE

LOW DISCHARGE PRESSURE AND/OR SUCTION PRESSURE LOW

CHECK THE SIGHT GLASS (7, fig. 15)

EXCESSIVE REFRIGERANT IN SYSTEM Note: bubbles could be visible in the sight glass. Evacuate refrigerant until a large number of bubbles appear in the sight glass, then add refrigerant to the system until the bubbles disappear

BUBBLES IN SIGHT GLASS Insufficient refrigerant. Possibly due to small leaks. 1. Check system for leaks and eliminate if found. 2. Add refrigerant until the bubbles disappear and both pressure gauges show normal readings.

DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL

Note: during testing, the low pressure gauge reading could fall to negative values or remain normal. HUMIDITY IN THE SYSTEM 1. Evacuate the refrigerant from the system. 2. Replace the filter--dryer. 3. Remove all air from the system then proceed with re--charging.

CONDENSER 1. The condenser could be clogged or it might not be receiving an adequate air flow. Clean condenser fins.

EXPANSION VALVE Check the valve, as indicated on page 9. 1. If the valve fails the test, replace it.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) COOLING INSUFFICIENT

HIGH DISCHARGE PRESSURE AND/OR NORMAL SUCTION PRESSURE

HIGH DISCHARGE PRESSURE AND/OR SUCTION PRESSURE LOW

DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL/HIGH

Note: The high pressure gauge reading should be constant and should not fall.

RESTRICTION Water or ice forms downstream of the restriction (on receiver--drier or on the pipe between the condenser outlet and the expansion valve). 1. Remove the relevant component and eliminate the restriction or replace the component.

ANTI--FROST SWITCH With the outside temperature below 30_ the electro--magnetic clutch is permanently engaged. 1. Check as described on page 10. 2. Replace the anti--frost switch if it does not function correctly, taking care not to crush the capillary tube. Install the new switch in the same position on the evaporator outlet pipe as the switch that has been replaced.

AIR IN SYSTEM 1. Recover--recycle the refrigerant in the system. 2. Replace the filter--dryer. 3. Evacuate the system and then re--charge.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

AIR CONDITIONING SYSTEM TROUBLESHOOTING (CONT.) COMPRESSOR AND ELECTRO MAGNETIC CLUTCH

UNUSUAL NOISE WITH CLUTCH ENGAGED

1. Check all compressor mountings. 2. Check engine components in the vicinity of the compressor. 3. Check if the electromagnetic clutch operates intermittently or slips.

4. Check the clutch bearing. 5. Check that the clutch pulley runs freely. 6. Check the oil level in the compressor.

LACK OF COOLING

The compressor runs noisily or does not run.

ABNORMAL NOISE WITH CLUTCH DISENGAGED OR VIBRATION

1. Check electrical power supply. 2. Check the clearance between the front disk and the pulley.

1. Check the condition, pulley alignment and tension of the compressor drive belt. 2. Check the clearance between the front disk and the pulley of the electromagnetic clutch. 3. Check the clutch power supply, the current absorbed, the power supply wire, and the ground connection.

4. Check that the clutch pulley runs freely. 5. Check that there is sufficient refrigerant in the system. 6. Check the compressor for leaks. 7. Check the system for leaks.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 ATTENTION

During these operations, follow the safety instructions and instructions for use described at the start of Section 50. Handle all parts with great care, always use safety goggles, gloves and shoes.

REFRIGERANT RECOVERY--RECYCLING AND EVACUATION--CHARGING STATIONS

ATTENTION Do not use recovery/recycling and system emptying/charging machines which are designed for use with a refrigerant type other than that used in the system. Different types of refrigerant have different chemical compositions and are incompatible. Connecting the piping to the stations When connecting the stations to the system service valves, always connect the low pressure blue pipes (11, fig. 17, or 17, fig. 18), to the service valve on the suction side of the compressor (S--Suction), and the high pressure red pipes (12, fig. 17, or 15, fig. 18), to the service valve on the discharge side of the compressor (D--Discharge). Important: check the seals in the pipe unions (11, 12, 16, fig. 17), or (15, 17, 24, fig. 18) and replace if faulty. Remember that pipe fittings with seals must be hand--tightened only without forcing, otherwise the seal may be damaged. RECOVERY AND RECYCLING STATION (380000315) Description (Refer to figure 17) The machine is designed to recover and recycle the refrigerant used in air conditioning systems. Recovered refrigerant is first subjected to an evaporation process in a special chamber to remove any oil. In the filter section, the acidity is neutralised, moisture is absorbed and solid particles are screened out. The decontaminated refrigerant is then stored in the metering cylinder.

CHARACTERISTICS Recovery compressor equipped with oil level indicator, discharge valve and service connection. Anti--acid decontaminating filter (3), with high moisture absorption capacity.

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Refrigerant/oil distillation cylinder (4) with heating element, automatic device for return of oil to the recovery station compressor and automatic flow control valve for refrigerant entering the station. Graduated cylinder (19) for recovered refrigerant, 2.2 kg capacity, with heater and a safety valve. 2--way pressure gauge unit, with refrigerant flow indicator and pressure gauges (1 and 2) controlling the pressure in the cylinder and at the inlet. Humidity indicator (15) for checking the decontaminated refrigerant. Low pressure switch for automatic cycling of the compressor. Graduated container for discharge of recovered contaminated oil. Switch (5) 1--0--2 for recovery and cylinder heating. Operation indicator lights. Flexible service pipes (11, 12 and 16) with safety cocks. Recovery capacity: 200 grams/minute. Power: 220 V (50 Hz). Service Replacement of refrigerant decontamination filter (3) Refer to figure 18, proceed as follows: Warning -- Replace the filter (3) every 12 months, or earlier if the humidity indicator (15) becomes yellow (and remains this colour) during the recovery/recirculation phase. 1. Close all the valves including the yellow service valve (9) installed below the distillation cylinder (4). 2. If refrigerant is present in the circuit set push button (5) to position â&#x20AC;?1â&#x20AC;? and carry out the refrigerant recovery operation. The compressor will stop automatically when the pressure gauge (2) drops to --0.3 bar. 3. Remove and replace the contaminated filter (3). 4. Carry out a normal evacuation operation for approx. 30 minutes, using the recycling, evacuation and charging system (380000315) proceeding as follows: connect the pipe (17, fig. 18) to the service valve (14, fig. 17), open the cock on the pipe and cocks (4, 9 and 10, fig. 18). On completion of the evacuation operation, close cocks (4, 9 and 10), the cock fitted on the pipe (17) and disconnect pipe (17).

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Check filter connections for leaks (3)

RECYCLING, EVACUATION AND CHARGING STATION (380000315)

Refer to figure 17, proceed as follows: 5. To check for leaks at the connections of the previously replaced filter (3) open the yellow service cock (9) on the distillation cylinder (4).. 6. Carry out a brief recycling operation on the refrigerant contained in the cylinder (19), proceeding as described in operations 18รท21, and, using a leak detector, check for leaks at the connections of the new filter. 7. Record the operation on the appropriate service report card. Changing the compressor oil in the recovery/recycling station

Description (Refer to figure 18) The machine is designed for emptying and charging air conditioning systems with refrigerant. The emptying stage is necessary to remove any moisture and impurities from the system. The refrigerant drawn from the system is transferred to a graduated cylinder, from which it subsequently pumped into the air conditioning system.

Refer to figure 17, proceed as follows:

Technical characteristics

Warning -- The oil in the recovery/recycling station compressor should be replaced with new oil every 12 months, in order to maintain station refrigerant treatment capacity and to protect the compressor.

Double--acting, ballasted, rotary vacuum pump (21) in oil bath.

1. Open cock (13), and drain the oil into a container to be disposed of in accordance with local regulations for waste oil disposal.

Charging cylinder (31) with maximum level indicator and graduated scale for measurement of quantity of refrigerant.

2. Close cock (13).

5--way pressure gauge manifold with 2 pressure gauges (5 and 6) and 1 vacuum meter (8).

3. Remove the caps from the service valves (14) on the side of the compressor and (13) on the sight glass.

Flexible service pipes (15, 17 and 24) with safety cocks: Power: 220V (50 Hz).

4. Connect the service pipe of the evacuation station to valve (14) and connect a suction pipe to valve (13) on the sight glass.

Service

5. Perform the evacuation operation with the pump in operation. The new oil can be aspirated from an external container by means of the suction pipe. 6. Once the compressor has been filled with correct quantity of oil (half--way up the sight glass) close valve (13), disconnect the pick--up pipe, and replace the cap on service valve (13). Continue the evacuation for approx. 30 minutes. 7. On conclusion, close the cocks, switch off the pump, disconnect the service pipe and replace the cap on service valve (14).

Check level and change oil in pump of evacuation/charging station (periodic check) Refer to figure 18, proceed as follows: Periodically check the level and condition of the oil. Drain off the old oil, if necessary, through plug (18). This oil must be discharged and disposed of (in accordance with applicable regulations on the disposal of used oil). Remove cap (13) and fill the vacuum pump (21) with new oil of the type indicated by the pump manufacturer up to the half--way line on the sight glass (14).

8. Record the operation on the appropriate service report card.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

OP. 50 200 04 DEHYDRATION , RECHARGING AND REFRIGERATION CHECK Recovery of refrigerant from the cab air conditioning system using the recovery/recycling station 380000315

ATTENTION During operation 5020004, follow the safety instructions and instructions for use described at the start of Section 50. Handle all parts with great care, always use safety goggles, gloves and shoes.

NOTE: The recovery operation can be performed quicker and more completely if the system is previously heated. The heat will help the refrigerant to evaporate, facilitating evacuation from the system. Refer to figure 17 and proceed as follows: 1. If possible, operate the air conditioning system for a few minutes with the tractor engine running and the hood down, so that the heat produced is gradually transferred to the various components in the system, thus allowing any pockets of very cold fluid in the system to evaporate. 2. Stop the engine.

DANGER The recovery operation must only be performed with the tractor engine stopped. 3. If the charging cylinder (19) already contains refrigerant, check that there is still sufficient free volume to contain all the refrigerant in the system (maximum cylinder capacity is 2 kg); if not, transfer the excess refrigerant to an external cylinder in the manner described on page 26. 4. Connect the station’s supply lead to a power outlet. 5. Make sure that all cocks are closed except the service cock (9). 6. Remove the caps from the service valves installed on the suction and discharge lines of the compressor. 7. Connect the blue service pipe (11) to the valve on the suction (low pressure) side of the compressor (marked ”S”).

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8. Connect the red service pipe (12) to the valve on the discharge (high pressure) side of the compressor (marked ”D”). 9. Switch on the cab ventilation fan at maximum speed to assist the transfer of heat between the ambient air and the evaporator coil. 10. Open the cocks (10) fitted on pipes (11 and 12). 11. Slowly open cock (6--LOW) on the pressure gauge manifold. Pressure gauge (2) will indicate the pressure of the refrigerant in the system; if the needle is near ”0”, the system is empty. 12. Set switch (5) to position ”1” (RECOVERY) -green indicator light will illuminate. The recovery unit compressor will start. During the recovery operation the refrigerant passes through the distillation chamber (where the oil is separated out), the purification filter (where most of the impurities are filtered out), and then finally arrives at the graduated cylinder. The compressor stops automatically when the pressure gauge (2) shows --0.3 bar. 13. Wait a few minutes to allow any pockets of liquid refrigerant left in the system to evaporate and be evacuated. 14. Check the pressure gauge (2): if the pressure rises above the previous absolute value of --0.3 bar, the station will automatically start a second recovery operation. If, on the other hand, the pressure has remained near the value obtained during the first recovery operation, this indicates that all of the refrigerant has been recovered and the operation is completed.

NOTE: If after 10 minutes of operation the station has not recovered more than 1 kg of refrigerant, check the pressure gauge (1). If the pressure reading is over 10 bar open cock (21) and discharge air, then check that pressure gauge (1) does not exceed a maximum of 10 bar throughout the entire recovery operation. 15. Close all the cocks except cock (9), disconnect the service pipes (11 and 12) from the air conditioning system compressor and switch off the station. 16. Switch off the cab ventilation fan.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

19. Connect the 2 ends of the yellow (16) and blue (11) pipes with the connector supplied.

Recycling of recovered refrigerant On completion of the recovery operation , the refrigerant must completely purified.

ATTENTION Recovered refrigerant must be completely purified before it can be re--used.

Proceed as follows: 17. All cocks must be closed, with the exception of cock (9, fig. 17) and the station must be switched off -- switch (5) in position ”0” and the green indicator light off. 18. Connect the end of the yellow service pipe (16) to the free connector (17) located on the left--hand side of the pressure gauge manifold.

20. Slowly open the cock (18--REF) and the blue cock (6--LOW) on the pressure gauge manifold, and the cocks on the two previously connected service pipes (16 and 11). 21. Set switch (5) in position ”1” (RECOVERY), green indicator light on. The recovery compressor will start to operate and the refrigerant will pass from the graduated cylinder to the recovery circuit (distillation cylinder, filter and compressor) and then return to the graduated cylinder. 22. Continue the operation until the circular sector of the humidity indicator (15) becomes green. If, after 15 minutes, the circular sector of the indicator (15) still has not turned green, replace the filter (3), as described on page 22.

7 8 9

17 25378

10 17

Refrigerant recovery and recycling station 12. Red service pipe for connection to discharge side of 1. Cylinder pressure gauge. compressor. 2. Recovery control pressure gauge. 13. Recovery compressor oil discharge cock. 3. Anti--acid and decontamination filter. 14. Recovery compressor service valve (suction). 4. Recovered refrigerant/oil distillation cylinder. 15. Humidity indicator. 5. Switch. 16. Yellow service pipe for refrigerant transfer. 6. Refrigerant inlet control cock (LOW). 17. Fitting for refrigerant transfer. 7. Recovered oil discharge cock (yellow). 18. Cock (REF) for refrigerant transfer. 8. Recovered oil discharge pipe. 19. Refrigerant cylinder. 9. Oil return to compressor control cock (yellow). 20. Safety valve. 10. Quick--fit connectors. 21. Yellow cylinder discharge cock (gaseous stage). 11. Blue service pipe for connection to suction side of compressor.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

NOTE: The circular sector of the humidity indicator (15, fig. 17) must remain green throughout the recycling operation. If the colour of the sector tends to vary between yellow and green, or turns completely yellow, , this means that the filter is saturated with moisture and therefore must be replaced. 23. On completion of the decontamination operation, close the yellow cock (18--REF) and continue to recover the refrigerant. The compressor will stop automatically when the pressure gauge (2) indicates a pressure of --0.3 bar. 24. Close the cock (6--LOW), the two cocks on the ends of the yellow (16) and blue (11) service pipes, disconnect pipes (16 and 11) and switch off the station, turning switch (5) to position ”0”. Discharge of recovered oil On completion of the recovery operation, any contaminated oil will be visible in the distillation chamber (4). This oil must be discharged and disposed of (in accordance with applicable regulations on the disposal of used oil). Proceed as follows: 25. Slowly open the yellow cock (7) and discharge the recovered oil in the graduated container. 26. If no refrigerant leaks, whether major or minor, have ever been detected in the system, on recharging, replace the contaminated oil with same quantity of new oil (see page28). Transfer of decontaminated refrigerant from cylinder (19) to an external cylinder If for any reason the decontaminated refrigerant is not to be put back into the air conditioning system immediately, for reasons of safety it must be transferred from cylinder (19) to a homologated refillable gas container. Proceed as follows: 27. Check that all the cocks are closed with the exception of cock (9) and that the station is switched off. Check that the container (cylinder) is large enough to contain all the refrigerant to be transferred without exceeding the permitted safety level. 28. Connect the end of the yellow service pipe (16) without the cock to the free connector (17) on the

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left--hand side of the pressure gauge manifold, and connect the other end (with the cock) to the red connector of the external cylinder. 29. Set switch (5) to position ”2” HEATING CYLINDER to switch on the refrigerant heater fitted to the cylinder (19) so as to facilitate the transfer of the refrigerant from the cylinder to the external cylinder. 30. Open the yellow cock (18--REF), the yellow cock on the service pipe and red cock on the external cylinder. 31. On completion of the transfer, close all cocks and switch off the station by turning switch (5) to position 0. Evacuation and charging the cab air conditioning system using the recycling, evacuation and charging station 380000315. NOTE: Operations 32 ÷ 34 must only be carried out if there is no refrigerant in the graduated cylinder (31, fig. 18).

Evacuation of the graduated cylinder (31) of the evacuation/charging station Refer to figure 18, proceed as follows: 32. Close cocks (4, 22 and 27). 33. Open cocks (3, 9 and 10). 34. Start the pump by turning switch (19) to position ”1” to evacuate the cylinder (31). After 5 minutes close cocks (3, 9 and 10) and switch off the pump. Charging the graduated cylinder (31) of the evacuation/charging station If the decontaminated refrigerant in the recovery/recycling station is to be immediately put back into the tractor air conditioning system, it must be transferred from cylinder (19, fig. 17) to cylinder (31, fig. 18) of the evacuation/charging station, proceeding as follows. 35. Using figure 18, connect the end of the yellow service pipe (24) without the cock to the free connector (28) on the left--hand side of the evacuation/charging pressure gauge.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 36. Connect the other end (with the cock) to the free connector (17, fig. 17) on the left--hand side of the recovery/recycling station pressure gauge manifold. 37. Using figure 18 for reference, check that all the cocks of the recovery/recycling station are closed, apart from cocks (9 and 17) and the cock fitted on the pipe (16). 38. Check that all the evacuation/charging station cocks are closed, apart from cock (27, fig. 18). 39. Check that the stations are switched off with switches (5 and 18) in position ”0”. 40. Using figure 18 for reference, turn switch (5) to position ”2” HEATING CYLINDER to switch on the refrigerant heater installed on the cylinder (19), to facilitate the transfer of refrigerant to cylinder (31, fig. 18) of the evacuation/charging station.

41. On completion of the refrigerant transfer operation, close all of the cocks, apart from cock (9, fig. 17) and switch off the recovery/recycling station by turning the switch (5) to position ”0”. 42. Check the quantity of refrigerant in the graduated cylinder (31, fig. 18). 43. From the total quantity of refrigerant required in the air conditioning system indicated in the note on the following page, calculate the quantity of refrigerant that must be added to the cylinder (31) to make up the total amount required. 44. Transfer refrigerant from the external cylinder to the graduated cylinder (31) proceeding as follows. 45. Connect the yellow pipe (24) to connector (28) and to the external cylinder containing the refrigerant (upside down if not equipped with an outlet valve. 46. Open the cock on the external cylinder, the cock on the charging pipe (24) and cock (27).

8 9

25 24 25378

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

23 22 21 20 19 18 17

Evacuation/charging station. 17. Blue service pipe for connection to suction side of Safety valve. compressor. Cylinder pressure gauge. 18. Oil drain plug. Refrigerant charging cock. 19. On/Off switch (I), heater (II). Low pressure side cock (LOW). 20. Oil meter connector. Low pressure gauge. 21. Vacuum pump. High pressure gauge (red). 22. High pressure side cock (HIGH). 5--way pressure gauge manifold. 23. Sight glass. Vacuum meter. 24. Yellow service pipe. Vacuum test cock (VAC). 25. Cylinder heater. Vacuum meter test cock. 26. External ring. Vacuum meter safety valve. 27. Refrigerant transfer cock (REF). Oil charging cock. 28. Refrigerant transfer connector. Oil filler cap. 29. Glass rod. Sight glass. 30. Outer casing (Plexiglass). Red service pipe for connection to discharge side of 31. Refrigerant charging cylinder. compressor. Quick--fit connectors.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

47. Rotate the outer casing (30) so that pressure value indicated on the graduated scale corresponds with the value shown on pressure gauge (2). 48. When the refrigerant in the cylinder has reached the required level, as indicated on the glass rod (29), close the cock of the external cylinder, the cock on the charging pipe (24) and cock (27). NOTE: If excessive time is required to transfer refrigerant from the external cylinder to cylinder (31), slightly open valve (1) and discharge air from the cylinder (31); the pressure reading on pressure gauge (2) should not exceed 5 bar.

proceed with the compressor oil level check procedure described on page 7. Refer to figure 18, proceed as follows: 56. 57. 58. 59.

Pour the oil into the graduated oil meter. Connect the oil meter to the oil meter (20). Close cocks (4 and 10). Set switch (19) to position ”2” to switch on the refrigerant heater on cylinder (31). 60. Open cock (12) and the cock on the graduated oil meter. 61. Check the quantity of oil flowing from the oil meter, and once the required quantity has been reached, close cocks (12) and the cock on the oil meter, and remove the graduated meter.

Evacuation of the cab air conditioning system (previously discharged using the recovery/recycling station)

Charging the cab air conditioning system with refrigerant (after evacuation)

49. Remove the caps from the service valves on the suction and discharge lines of the compressor. Refer to figure 18, proceed as follows: 50. Connect the blue service pipe (17) to the valve on the low pressure side of the compressor marked ”S”. 51. Connect the red service pipe (15) to the valve on the high pressure side of the compressor marked ”D”. 52. Open the quick--fit cocks (16). 53. Open cocks (4 -- 9 -- 10 -- 22). 54. Start the pump by turning switch (19) to position ”I” and evacuate the system for at least thirty minutes; pressure gauges (5 -- 6 -- 8) should show a negative reading. If the evacuation operation is not performed correctly, check all connections. 55. Close cock (9), switch off the pump by turning switch (19) to position ”0” and check the vacuum seal for at least five minutes using vacuum meter (8). Then close all cocks.

NOTE: The quantity of refrigerant required to be introduced into the system is 1300 grams (R134a refrigerant).

Charging the cab air conditioning system (after evacuation) with new oil If no refrigerant leaks, whether major or minor, have ever been found in the system, on recharging, replace the contaminated oil previously recovered in operations (25 and 26) with new oil. If, on the contrary, significant leaks have occurred in the past,

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Refer to figure 18, proceed as follows: 62. Keep switch (19) in position 2, with the refrigerant heater in cylinder (31) on, and heat the refrigerant for approx. 10 ÷ 15 minutes to facilitate transfer from the cylinder to the tractor air conditioning system. 63. According to the refrigerant type, rotate the outer casing (30) so that the graduated scale and the pressure values correspond with the pressure reading on gauge (2). 64. Move the external ring (26) along the cylinder glass to mark the quantity of refrigerant to be charged. 65. Open cock (22) and charge from the high pressure side. 66. Open cock (3), charge approx. 300 grams of refrigerant, close cock (3) and check for leaks. 67. If there are no leaks, continue charging up to the prescribed quantity. 68. On completion of charging, turn switch (19) back to position ”0”, close cocks (3 and 22), disconnect pipes (15 and 17), and replace the caps on the service valves. Carry out functional tests with the system set to maximum performance levels, as described below.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

SUMMARY OF THE AIR CONDITIONING SYSTEM CHARGING OPERATIONS NOTE: The pressure readings noted below are valid for an ambient temperature of 25Â°C --

Pressure gauge readings on completion of refrigerant recovery and recycling operation.

25381

19 --

Pressure gauge readings with cocks (4 -- 9 -- 10 and 22, fig. 18) open, cylinder (31) with 1600 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) closed and compressor cut off.

25382

20 --

25383

21 --

25384

22 84419869A - 11 - 2007

30 --

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1 Pressure gauge readings with cocks (4 -- 10 -- 22, fig. 18) open, cylinder (31) with 1600 grams of refrigerant, red and blue service pipes connected to the tractor system, cocks (16) open, compressor off and cock (9) closed (check on vacuum meter (8) that no pressure drops occur over a period of five minutes).

25385

23 --

Pressure gauge readings (start of charging -- end of charging). All previously opened cocks are to be closed, apart from cocks (3 and 4, fig. 18), compressor off. The level of refrigerant in the charging cylinder can be seen to drop; proceed until only 300 grams of refrigerant remain in the charging cylinder (1300 transferred). The reading on vacuum meter (8) remains the same from the beginning to the end of the charging operation.

25386

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

OP. 50 200 06 CHECKS AND EVENTUAL ELIMINATION OF GAS LEAKS

Testing for leaks with leak detector 380000314

With the system charged and the pressure gauges connected, proceed as follows:

6. Switch on the electronic leak detector.

7. Move the probe around all pipe connections and all possible points of leakage:

The presence of refrigerant, and thus al leak, is signalled by an increase in the frequency of the audible signal.

1. Start the engine.

2. Check that the knob (2) is turned fully to the left (maximum cold), so as to turn off the heating function.

3. Set the cab ventilation fan (1) to maximum speed.

NOTE: The refrigerant is heavier than air, therefore it will be easier to detect the leak point from below rather than from above. 8. If leaks are found in the pipe connections, tighten the fittings in order to eliminate the leak.

4. Turn the knob (1) to turn on the air--conditioner.

5. Bring the engine up to a speed of 1500 rpm.

Caution -- If any of the system components need to be replaced, always follow the recovery, recycling and charging operations described in operation 50 200 04.

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

CHECKING FOR REFRIGERANT LEAKS USING AN ELECTRONIC LEAK DETECTOR

Leak detector (380000314) The leak detector 380000314 is supplied in its own carrying case which also contains the two power supply batteries, the sensitivity test phial and an ear plug connection for audible leak indication. The instrument comprises the main unit and the flexible probe which contain the sensor at the tip. To correctly position the flexible probe, slacken off (counter--clockwise) the thumbscrew located on the bottom left--hand corner of the case. Mounted on the front of the instrument are the on/off switch, the red on/off LED and the acoustic gas detection indicator. The socket for the headset connection is on the rear of the instrument. The battery compartment also houses the sensor element and a number of replacement felts.

Refrigerant gas leak test The detector automatically adjusts its sensitivity in accordance with the quantity of gas present in air around the sensor tip when switched on and off. In ventilated airs it can be extremely difficult to locate the source of a gas leak; in this case it will be necessary to screen off the area in which the leak is suspected to obtain more accurate readings. In cases where the presence of large leaks masks smaller leaks, first locate and repair the large leaks before attempting to locate the smaller leaks. Service Always make sure that the detector is switched off before replacing the sensor element. To replace, rotate the probe counter--clockwise, install a new element and new felt pad rotating it clockwise on the flexible probe. Do not switch on the detector until the new sensor is screwed firmly on to the end of the flexible probe. Be careful to avoid getting grease or grit in the hole connecting the probe with the sensor element.

Use

Put the switch into the ON position: start looking for leaks; the amplitude of the acoustic signal increases as the sensor approaches the source of a leak. In the area around the leak, switch the instrument on and off again; the instrument will automatically switch to a new acoustic level. Carry out the following test each time you use the detector. Hold the sensor element close to the open sensitivity test phial; when the detector starts to emit an audible signal, switch it on and off. If the amplitude signal continues to increase, switch the instrument on and off again.

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25388

26 Leak detector probe 1. Flexible probe. 2. Sensing tip. 3. Felt pad. 4. Guard.

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Op. 50 206 51 CAB HEATING/AIR CONDITIONING SYSTEM Removal -- Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 150 10 Cab with platform unit, only removal (see Sect. 90, chapter 1). 2. Take off the cover with the logo from the steering wheel (1), using the tool 380000223 (2) detach the steering wheel (1).

3. Unscrew the retaining bolts and remove the black guard (1).

28 4. Unscrew all the retaining bolts and remove the grey guard (1). 5. Remove the relevant screws and detach the power shuttle control lever (5). 6. Remove the relevant screws, detach the electric connections and remove the control panel (2). 7. Mark and disconnect the connections of the ignition block (3). 8. Detach the rear guard (4) of the steering wheel. 29

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SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

9. Unscrew the relevant retaining bolts and remove the two shrouds (1).

30 10. Disconnect the electric connections (1) of the thermostat and of the cab air--conditioning/heating system relay.

31 11. Unscrew the retaining bolts and detach the radiator/evaporator assembly (1) from its support. 12. Install the cab air--conditioning/heating system radiator assembly considering the following warnings.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Position and secure the cab air--conditioning/heating radiator assembly.

Connect the electrical connections of the thermostat and relay.

Position and secure the two shrouds.

Position and secure the steering column rear guard.

---

Position and secure the steering block and connect the relevant electric connections. Position and secure the control panel and connect the electric connections.

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32 --

Position and secure the power shuttle control lever.

Position and secure the grey guard.

Position and secure the black guard.

Position and secure the steering wheel, insert the cover with the logo on the steering wheel.

Carry out operation 90 150 10 Cab with platform unit, only installation (see Sect. 90, chapter 1).

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Op. 50 206 62 ELECTRIC FAN UNIT CAB Removal -- Installation

2. Unscrew the relative retaining bolts and detach the seat (1).

34 3. Unscrew the relative retaining bolts and detach the seat support (1).

35 4. Disconnect the electric connection (1), unscrew the relevant fixing screws and detach the fan (2). Do this on both sides. 5. Install the cab air--conditioning and heating system fans considering the following warnings.

ATTENTION

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ----

Position the fan and secure it by means of the relevant screws, connect the electric connection. Do this on both sides. Position and secure the seat support. Position and secure the seat, connect the relevant electric connection.

36 84419869A - 11 - 2007

SECTION 50 -- CAB AIR CONDITIONING SYSTEM -- CHAPTER 1

Op. 50 200 72 AIR--CONDITIONING SYSTEM Removal -- Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Raise the bonnet. 2. Connect the connections (1 and 2), of the recovery station 380000315, to the appropriate connections on the cab air--conditioning system pipes and drain off the refrigerant from the system. 3. Mark the pipes (1) and disconnect them from the cab air--conditioning system condenser.

38 4. Unscrew the relevant bracket fixing screws (1) and extract it together with the condenser (2). 5. Install the cab air--conditioning system condenser considering the following warnings.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ----

---

Position the condenser and secure it with the relevant bracket. Connect the piping to the condenser. Connect the charging station 380000315 to the appropriate connections and charge the cab air--conditioning system. Perform cab air--conditioning system functional testing. Close the bonnet.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Instruments CONTENTS Section

Description

Page

Analog digital instrument for models Powerstar T4.55, T4.65 and T4.75 . . . . . . . . . . . . . . 2 Cross--sectional views of the Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Deletion of working hours . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Setting the hour counter on a new ADIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Deletion of auto--configuration of speed sensor and seat with operator presence switch

Speed calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Indicator lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Cross--sectional views of the panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Transmitters, sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electronic control unit inputs/outputs (ADIC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 DIGITAL ANALOG INSTRUMENT FOR MOD. Powerstar T4.55, T4.65 AND T4.75.

MDQ0151A

1 The analogue instrument panel consists of six display sections: 1. Speedometer/tachometer.

3. Engine coolant temperature gauge.

2. LCD panel with indicator showing faults, engine hours and speed.

4. Fuel gauge.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

CROSS--SECTIONAL VIEWS OF THE PANEL Speedometer/tachometer

Speedometer/tachometer for models T4.55, T4.65 and T4.75 with F5A engine. Shows the revs of the power take--off: 540E

1592 rpm

Red

NASO--ISO

540

1958 rpm

Black

ISO

540

2160 rpm

Black

NASO MDQ0152A

2 LCD panel. The LCD panel can provide three pieces of information: -- Speed (1) in km/h or MPH (if the sensor measuring the theoretical speed is fitted). -- Fault indicator (2). The symbol appears on detecting a fault, short circuit to ground, to +12 volts or open circuit, on the seat switch. -- Hour counter. MDQ0153A

3 To pass from the hour display to the speed display, use the Home / Enter button (1) fitted on the control panel under the steering wheel. Press the Enter button (on the right--hand side) for a time of â&#x2030;¤3 seconds to pass from displaying the hours to displaying the speed. The display shown at the time of key--off will be what appears at the next power--up (key--on). Press the Enter button (on the right--hand side) for a time of > 3 seconds to enter the settings menu, where you can calibrate the speed. Press and release the Home button (on the left--hand side) for a time of > 3 seconds with the speed shown on the LCD and the machine stationary to pass from km/h to MPH.

MDQ0154A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Deletion of working hours. Key--on After 40 sec.

After 30 sec.

After 45 sec.

ENTER Within 3 sec.

If 3 deletions available

Hours worked blink

Deletion hours worked

After 2 sec. MDQ0155A

5 It is possible to delete the hours worked on the LCD of the ADIC, if the total hours do not exceed 20 for 3 times. Proceed as follows. --

Press the Home / Enter button on the left--hand side while turning the key onto power, then release it.

Press it again within 3 seconds and keep it pressed for a time of at least 45 seconds.

After approximately 30 seconds, the display of the hours on the dashboard will blink.

Once the Enter button has been pressed for 40 seconds the LCD will show one of the following letters: • H: if there are 3 deletions available • F: if there are 2 deletions available • L: for the last deletion available.

If the Enter button is now released the procedure will be interrupted.

If, vice versa, the button remains pressed for another 5 seconds (a total of 45 seconds) the deletion is carried out and the display will show the next letter to indicate the available number of deletions.

After approximately 2 seconds the display will show 0.0.

Release the Enter button.

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MDQ0154A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Setting the hour counter on a new ADIC. In order to allow the service to install a new ADIC on an old tractor, it must be possible to increase (no decrease shall be allowed) the hour counter value in order to have the same setting as the original. To set, proceed as follows. -- Press the Home / Enter button on the left--hand side while turning the key onto power, then release it. -- Press it again within 3 seconds. -- Keep it pressed for a time of: 30 < t > 40, The hour counter display will begin to blink. -- From this moment press: â&#x20AC;˘ the Enter switch to increase, â&#x20AC;˘ the Home switch to decrease. -- After setting the desired value, switch off to complete the setting procedure updating the value of the hour counter.

MDQ0154A

Deletion of auto--configuration of speed sensor and seat with operator presence switch (ISO markets). Key--on After 30 sec.

After 40 sec.

After 45 sec.

HOME Option deleted

Within 3 sec.

Hours worked After a key cycle.

MDQ0156A

8 If you want to re--use an ADIC already fitted on tractors with a theoretical speed sensor or operator presence switch on the seat in tractors where there are none of these variants. The ADIC has already performed auto--configuration with the presence of these two sensors at the first switch--on, the LCD will, at least, show a question mark to signal an anomaly on the switch, proceed as follows to delete the configuration.

MDQ0154A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

6 --

Press the Home / Enter button (1, fig. 9) on the right--hand side while turning the key onto power, then release it.

Press it again within 3 seconds and keep it pressed for a time of at least 45 seconds.

Once the Home button has been pressed for 40 seconds the LCD will show a number.

If the Enter button is now released the procedure will be interrupted.

If, vice versa, the button remains pressed for another 5 seconds (a total of 45 seconds) the deletion is carried out and the display will show a 0.

After a key cycle (key off -- key on) the display will show the hours worked.

Release the Home button.

Speed calibration.

Example display

Complete value saved

If speed > 2 km/h

Press for 3 seconds

After 15 seconds Or press

Speed incorrect value not saved

If speed < 2 km/h

MDQ0157A

Speed calibration is necessary because the ADIC receives the signal from the sensor, then re--processes it according to the tractor tyres and calculates the speed. Find a flat stretch of 100 m with no bends and mark the beginning and end with two lines. Position the tractor approximately thirty metres before the beginning, go into the settings menu (by pressing the Enter button, on the right--hand side, for a time of > 3 seconds) and make the calibration in the following manner. -- Press and hold down the Home / Enter button (1) on the left--hand side (Enter) and turn the key onto power, release it after 3 seconds. -- The LCD will show CAL.

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MDQ0154A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 ---

----

---

With the key on power, start the tractor without passing onto key off. Keeping a speed above 2 km/h, press and release the Enter button when the front wheel passes over the first mark. The display will show ON. Press and release the Enter button with the wheel on the second mark. If the speed has remained above 2 km/h the calibration has been performed properly, the display will show CAL OK. Press Enter again, the display will show CAL press Home (button 1, fig. 11 on the left--hand side) to exit the settings menu, then switch off the tractor. If the calibration was not done correctly the display will show CAL KO. Press Home, the display will show CAL, and begin the calibration again.

Coolant temperature The following table gives the temperatures indicated in Â°C from C (cold) in an anti--clockwise direction to H (hot) with the respective degrees of temperature and conditions of use H

C 40_

60_

80_

105_

108_

Light Blue Low

120_ Red

Medium

High

Temperature

MDQ0158A

12 Fuel level The following table gives the resistances in Ohm from E (empty) in an anti--clockwise direction to F (full). F

E 276 Yellow

230.75 160.75

120.75

60.5

20.5

Light Blue

The indicator light (22., page 9) lights up with a resistance of â&#x2030;Ľ 246 Ohm. MDQ0159A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

INDICATOR LIGHTS.

MDQ0160A

Mechanical battery cut--off (Amber)

Not used. 2.

Differential lock (Amber)

Not used. 3.

Four--wheel drive ON (green)

Signals engagement four wheel drive. 4.

the electro--hydraulic

Rear power take--off (Amber)

Signals engagement of the power take--offs. 5.

Front power take--off (Amber)

Not used.

Left direction indicator (Green)

Signals switching on the left turn indicator and, simultaneously with the right direction indicator, when the hazard lights are switched on. If the direction indicator is activated for more than 60 seconds with the tractor in motion, and for more than 5 minutes with the tractor stationary, the ADIC activates a generic acoustic warning continually until the indicators stop blinking. In the case of the hazard lights, the buzzer does not start 7.

Work lights indicator (Amber)

Signals the work lights are on. 8. Direction indicators 1st trailer (Green) Signals the trailer direction indicators are on. Direction indicators 2nd trailer 9. (Green) Signals the trailer direction indicators are on. 10. Full beam headlights. (blue) Signals the full beam headlights are on.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1 11.

Parking lamps. (green)

Signals the parking lights and dipped beam headlights are on. If the lights are lit with each transition of the key the ADIC will emit a special beep of 4 pulses of 1 second each. Brake fluid level. 12. (Red) This lights up if the brake oil level drops under the minimum. 13. Parking brake applied. (Red) This lights up when the parking brake is applied. There are three conditions in which the ADIC associates a continuous beep, until the trouble ends, with the blinking of this indicator light. -- Key off brake not engaged -- Brake not engaged without the presence of the operator (with seat with operator presence switch). -- Tractor moving with brake engaged. Trailer brake. 14. (Red) Not used. 15. Not used. 16.

Uncoupled brake pedals. (Red) Engine oil pressure. (Red)

The indicator light comes on when the engine oil pressure drops below a minimum value. If with the key on power and the engine stationary the indicator light is on for 1 sec., if there is pressure the ADIC makes the indicator light blink, during start--up, with 500 r.p.m. and with pressure, the indicator light is kept on, to then switch off after a few seconds if this sensorâ&#x20AC;&#x2122;s contacts are kept open, therefore with the necessary pressure. Air filter clogged. 17. (Amber)

18.

Right--hand direction indicator. (Green)

Signals switching on the right turn indicator and, simultaneously with the left direction indicator, when the hazard lights are switched on. If the direction indicator is activated for more than 60 seconds with the tractor in motion, and for more than 5 minutes with the tractor stationary, the ADIC activates a generic acoustic warning continually until the indicators stop blinking. In the case of the hazard lights, the buzzer does not start 19.

Heater. (Amber)

The indicator light shows that the element is heating the air in the intake manifold. After turning the key onto power and after the ADIC has diagnosed the indicator lights the indicator light comes on for 1 sec and monitors the temperature coming from the water temperature sensor, if this is between --30 _C and 12 _C the ADIC begins the preheating phase continuing to keep the indicator light on, start up only after switching off. 20. Power steering pressure warning light. (Red) The indicator light shows that the outlet pressure on the power steering is under the minimum value. 21. Alternator not charging. (Red) The indicator light shows that the alternator is not charging, with the tractor idling and stationary the indicator light can also be on, after a slight acceleration it should go out. 22. Fuel reserve. (Amber) The indicator light shows that the level of fuel in the tank is low. 23. Water in fuel (Amber) The indicator light shows that there is water in the fuel in the precleaner filter.

The indicator light signals the air filter is blocked.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TRANSMITTERS, SENSORS AND SWITCHES

E MDQ0161A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

H K

MDQ0162A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

M L

P N O Q

MDQ0163A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

MDQ0164A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

T U

MDQ0165A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

TRANSMITTERS, SENSORS AND SWITCHES. D. A/C pressure sensor on drier filter SEN--009. This is the pressure switch, installed on the high--pressure line, of the refrigerating circuit and it is a safety device protecting the system. It has the double function of preventing the compressor from continuing to compress refrigerant if the pressure in the circuit is too high (avoiding explosions) or too low (avoiding seizure of the compressor). In the first case it trips if the refrigerant pressure is greater than 27 ± 1.5 bar opening the electric circuit that feeds the electromagnetic clutch of the compressor and closing it when the latter returns to pressure values of under 21 ± 1.5 bar. In the second case it opens the electric circuit if the pressure is less than 2 ± 0.75 bar and it closes it again when the latter returns to values greater than 2.15 ± 0.35 bar. The causes of the increase in pressure inside the refrigerating circuit may be different: flattening of the tubes, obstruction of the expansion valve, dirty condenser, etc. The pressures inside the circuit are instead low when the quantity of refrigerant is insufficient. Unless it is not a matter of accidental damage to some component that determines the rapid leakage of refrigerant, generally the operator recharges the system before the pressure switch trips since the system performance is insufficient (it does not cool). It receives current from the fuse F--5c 25 A via first the A/C switch SW--028 then the anti--frost thermostatic sensor SEN--044 and passes it to the relay RLY--8 that commands the electromagnetic clutch of the compressor. E. Tractor speed sensor SEN--010. Hall effect sensor reads the theoretical speed on the gear of the slow ranges and transmits it to the control panel (ADIC) that thanks to the calibration, taking account of the tyres, converts the frequency into theoretical speed, displaying it on the LCD. Resistance between pin 1 and pin 2 680 Ohm ± 5%. The sensor is powered via the fuse F--15 5A at pin 1, at pin 3 it receives a ground signal and from pin 2 there is the signal directed to pin 25 of the connector C--010 of the ADIC. F. KSB sensor (advance cut--out) SEN--004A. This is a thermal wax bulb, when it receives current from the coolant temperature switch, the current melts the waxy substance and frees a mechanical device that removes the start--up advance, thus making starting easier at low temperatures. It receives current from the temperature switch SW--008. G. Engine stop solenoid SOL--005. This is a normally closed solenoid valve that when energized it opens and sends fuel to the injection pump. It receives current from the fuse, key--controlled, F--9 7.5A; obviously, when turning the key off, it no longer supplies the fuse and the engine switches off. H. Gearbox neutral sensor (for manual transmissions) SEN--002. This sensor is composed of a normally closed switch, it acts on the stem of the shuttle engagement fork; this, when the shuttle is disengaged, does not compress the switch with the forward / reverse gear engaged it compresses the switch and causes it to turn off. This sensor is in the starting safety system with that of the power take--off SW--005A the tractor is started when both are closed. It takes current from the power take--off switch SW--005A and takes it to the coil of the relay RLY--27 that commands the starting relay coil RLY--MR1. I. A/C compressor electromagnetic clutch connector C--010A. Electromagnetic clutch that when powered transmits the drive from the crankshaft to the air conditioning refrigerant compressor. One pin of the connector is closed to ground, the other takes current from the circuit: fuse F--5c 25 A via first the A/C switch SW--028 then the anti--frost thermostatic sensor SEN--044 via the closing of the relay RLY--8 it takes current to the electromagnetic clutch connector of the compressor. 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

J. Handbrake switch SW--024. This normally closed switch is open when the brake is not engaged, the activity of this switch is to turn on the indicator light on the dashboard (indicator light 13. page 9). It receives current from the fuse under the battery F--14 5A and it takes it with the brake applied to the pin 8 of the connector C--010 of the ADIC. K. Engine rpm sensor SEN--009A. This is an inductive type of sensor, it produces signals obtained from lines of magnetic flux that are closed via the openings of a phonic wheel splined onto the crankshaft, the signal is used to drive the tachometer of the ADIC panel. Resistance between pin 1 and pin 2 900 Ohm. It receives a ground signal directly from the ADIC pin 6 connector C--009 to pin 2 and sends a signal from pin 1 to the connector of the ADIC C--009 to pin 24. L. Water--in--fuel sensor SEN--006. This is a sensor that captures a certain deposit of water in the fuel filter and sends a signal to the ADIC to turn on the relevant indicator light (indicator light 23. page 9). It receives a ground signal directly from the ADIC pin 6 connector C--009 to pin 2, power to pin 3 from fuse F--13 7,5A and delivers a signal from pin 1 to the ADIC connector C--010 to pin 11. M. Engine oil pressure switch SW--007. This switch is normally closed and it is open when there is oil under pressure in the engine, this serves to switch on the indicator light on the instrument panel (indicator light 16. page 9). Calibration of switch 0.6 to 0.9 bar. It receives a ground signal from the engine casing and sends a signal, with the switch on, to the pin 4 of the connector ADIC C--010. N. KSB switch SW--008. This is a normally closed switch and it opens according to the temperature: with an increasing temperature it opens the contacts to 63 ± 3 °C, with a decreasing temperature to 53 ± 3 °C, it feeds the KSB sensor SEN--004A. At pin 1 it receives current from the fuse F--9 7.5A and, with the contacts closed, from pin 2 it sends it to the KSB sensor SEN--004A. O. Engine coolant temperature sensor SEN--008. This is a sensor that contains two variable resistors that vary according to the temperature, only one connection is used and serves to make the temperature gauge work on the ADIC panel. It receives a ground signal at pin C of the sensor directly from the ADIC pin 6 connector C--009, from the pin A of the sensor it sends the signal to the pin 11 of the ADIC connector C--009. P. Power steering pressure switch (manual transmissions) SEN--003. This is a normally closed switch fitted on the outlet pipe of the power steering and detects the pressure of the oil, if the pressure decreases more than necessary the indicator light comes on (indicator light 20. page 9), it is used for low pressure hydraulic services, for example four wheel drive electro--hydraulic engagement. Pressure switch calibration: contacts closed with pressures from 1÷ ÷10 ± 0.5 bar. It receives a ground signal at a pin of the switch directly from the ADIC pin 6 connector C--009, from the other pin of the switch, with pressures below 10 bar, it sends the signal to the pin 16 of the ADIC connector C--010. On tractors with a cab, the relevant cables are the transmission cable and the main cable.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Q. Fuel level sensor SEN--004. This is a variable resistance, it changes according to the level of the fuel. The following table gives the resistances in Ohm from E (empty) to F (full). F

E 276

230.75

160.75

120.75

60.5

20.5

The fuel reserve indicator light (22. page 9) lights up with a resistance of ≥ 246 Ohm. It receives a ground signal at pin 2 of the sensor directly from the ADIC pin 6 connector C--009, from the pin 1 of the sensor it sends the signal to the pin 2 of the ADIC connector C--009. R. Power steering pressure switch (hydraulic transmissions) SEN--003. This is a normally closed switch fitted on the outlet pipe of the power steering and detects the pressure of the oil, if the pressure decreases more than necessary the indicator light comes on (indicator light 20. page 9), it is used for low pressure hydraulic services, for example four--wheel drive electro--hydraulic engagement. Pressure switch calibration: contacts closed with pressures from 1÷ ÷10 ± 0.5 bar. It receives a ground signal at a pin of the switch directly from the ADIC pin 6 connector C--009, from the other pin of the switch, with pressures below 10 bar, it sends the signal to the pin 16 of the ADIC connector C--010. S. Power take--off switch (hydraulic version) SW--005. This is a normally closed switch fitted on the cover of the hydraulic control valve, it works on the power take--off hydraulic clutch engagement spool. With the clutch engaged, its contacts are open, otherwise with the clutch disengaged its contacts are closed, this switch belongs to the starting safety system together with the neutral one (with the gearbox in neutral and the power take--off disengaged the tractor is started). Powered via fuse F--11 7.5 with the clutch disengaged the contacts are closed and the current passes and goes to the gearbox neutral sensor SEN--002 and to the pin 16 of the connector C--009 of the ADIC to switch off the power take--off engaged indicator light (4. page 8). T. Gearbox neutral sensor (for hydraulic transmissions) SEN--002. This sensor is composed of a normally closed switch, it works on the shuttle engagement spool, that, with the reverser disengaged, in neutral, the contacts are closed. This sensor is in the starting safety system with that of the power take--off SW--005A the tractor is started when both are closed. It takes current from the power take--off switch SW--005A and takes it to the coil of the relay RLY--27 that commands the starting relay coil RLY--MR1. U. Air filter clogged sensor SEN--012. This sensor measures the vacuum, in practice it is a vacuum gauge, with a vacuum of 62 mbar the contacts close and the indicator light comes on (24. page 9). It receives a ground signal and, with a certain vacuum and the contacts closed, it sends it to pin 3 of the connector C--010 of the ADIC. V. Four--wheel drive solenoid SOL--002. This solenoid is normally closed, when it is powered it opens and lets the oil pass, it has the function of switching off the four--wheel drive. Powered via the fuse F--12 10A through pins 30 and 87A of the switch relay RLY--7 and the normally closed pins of the brake pedal switches SW--027 and SW--026 and the four--wheel drive disengagement switch SW--021, on closing the switch the current energizes the solenoid valve, so the four--wheel drive disengages, and goes to pin 5 of the ADIC connector C--010 to turn off the indicator light (3. page 8).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

W. Power take--off switch (tractors with cab mechanical version) SW--005A. This is a normally open switch fitted on the power take--off clutch servocontrol. With the clutch engaged, its contacts are open, otherwise with the clutch disengaged its contacts are closed, this switch belongs to the starting safety system together with the neutral one (with the gearbox in neutral and the power take--off disengaged the tractor is started). Powered via fuse F--11 7.5 with the clutch disengaged the contacts are closed and the current passes and goes to the gearbox neutral sensor SEN--002 and to the pin 16 of the connector C--009 of the ADIC to switch off the power take--off engaged indicator light (4. page 8). X. Parking block switch (NASO with cab) SW--024A. This normally closed switch works on a stem moved by the range gear, it opens the contacts with the block not engaged, the activity of this switch is to turn on the indicator light on the dashboard (indicator light 13. page 9). It receives current from the fuse under the battery F--14 5A and it takes it with the brake applied to the pin 8 of the connector C--010 of the ADIC. On tractors with a cab, the relevant cables are the transmission cable and the main cable. Y. Switches for brake lights and for four--wheel drive SW--026 and SW--027. Switches with double contacts: pin 1 and 4 normally closed pin 2 and 3 normally open, (read note on assembly) are activated by the brake pedals with electro--hydraulic four--wheel drive there are both (four--wheel drive engagement logic with pedals pressed) on tractors with a mechanical four--wheel drive there is only the left one and this is used only to turn on the brake lights. The four--wheel drive solenoid valve SOL--002 is powered via the fuse F--12 10A through pins 30 and 87A of the switch relay RLY--7 and the normally closed pins of the brake pedal switches SW--027 and SW--026 and the four--wheel drive disengagement switch SW--021, on closing the switch the current energizes the solenoid valve, so the four--wheel drive disengages, simultaneously it goes to pin 5 of the ADIC connector C--010 to turn off the indicator light (3. page 8). We now have the four--wheel drive disengaged, the indicator light on the ADIC switched off, the fuse F--12 10A feeds the pin 2 of the switch SW--027, pressing the pedals closes the pins 2 and 3 of each switch the current passes through and reaches the pin 86 of the relay RLY--7 that switches over removing current to the four--wheel drive switch SW--021 then also to the solenoid valve SOL--002 and the four--wheel drive engages mechanically and on the ADIC, as there is no current to the pin 5 of the connector C--010, the indicator light comes on; after the relay switches over the current flows to turn on the brake lights. NOTE: Fitting the switches on the brake pedals (SW- 026 and SW- 027), above all with the electro--hydraulic 4WD version: these must be fitted not in the rest condition (released) but but in their working condition (already pressed). With the switches fitted, without operating the pedals, the pins 1 and 4 instead of being normally open become normally closed the pins 2 and 3 instead of being normally closed become normally open. They are shown on the diagram in the above--mentioned way without operating the pedals. For reasons of safety, any fault found on the switches and on the circuit, the brake lights will switch on (if there is current) and the 4WD will not disengage. Z. Brake fluid level switches SW--011. This is a float immersed in the brake oil, when it falls below a certain level the float closes the contacts and turns on the indicator light on the ADIC (12. page 9). It receives power at pin 3 from the fuse F--13 7.5A and sends a signal to the ADIC connector C--010 on pin 18.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

AA. Power take--off switches (tractors without cab mechanical version) SW--005A. On tractors without a cab, normally open switch fitted on the power take--off clutch engagement lever. With the clutch engaged, its contacts are open, otherwise with the clutch disengaged its contacts are closed, this switch belongs to the starting safety system together with the neutral one (with the gearbox in neutral and the power take--off disengaged the tractor is started). Powered via fuse F--11 7.5 with the clutch disengaged the contacts are closed and the current passes and goes to the gearbox neutral sensor SEN--002 and to the pin 16 of the connector C--009 of the ADIC to switch off the power take--off engaged indicator light (4. page 8). AB. Parking block switch (NASO without cab) SW--024A. This normally closed switch works on the parking block engagement / disengagement pedal, it opens the contacts with the block not engaged, the activity of this switch is to turn on the indicator light on the dashboard (indicator light 13. page 9). It receives current from the fuse under the battery F--14 5A and it takes it with the block applied to the pin 8 of the connector C--010 of the ADIC. On tractors without a cab the relevant cable is only the main cable. AC. Power steering pressure switch (tractors without a cab) SEN--003. This is a normally closed switch fitted on the outlet pipe of the power steering and detects the pressure of the oil, if the pressure decreases more than necessary the indicator light comes on (indicator light 20. page 9), it is used for low pressure hydraulic services, for example four--wheel drive electro--hydraulic engagement. Pressure switch calibration: contacts closed with pressures from 1÷ ÷10 ± 0.5 bar. It receives a ground signal at a pin of the switch directly from the ADIC pin 6 connector C--009, from the other pin of the switch, with pressures below 10 bar, it sends the signal to the pin 16 of the ADIC connector C--010. On tractors without a cab, the relevant cables are the engine cable and the main cable.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

ELECTRONIC CONTROL UNIT INPUTS/OUTPUTS (ADIC) CODE

DESCRIPTION

ALT--001

Alternator

BAT--001

Battery

C--005A

Diagnostic connector

MOD--001A

Fusemodul

MOD--001B

F- 1

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

F- 2

(+12V from F--M004) Hazard lights switch

F- 4

(+12V from pin 15--SW--715) Hazard lights switch

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting Home / Enter switch

F- 19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F20

(+12V from F--M004) Instrument panel power supply

Fuse and Relay module RLY- 7

MOD--001C

MOD--003

Fusemodul RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

(+12V from F--M004) Instrument panel power supply

Fusemodul F- 003

MOD--3/4

Brake lights

(+12V from F--M004) Full--beam/low--beam headlight switch

Power fuse module F- M004 Deck service 50A mega fuse

MOD--004

Electronic flasher module (ISO)

MOD--004A

Electronic flasher module (NASO)

MOD--1_ADIC Control panel module RLY--001GH

Grid heater relay

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

CODE

DESCRIPTION

SEN--003

Steering Pressure Switch

SEN--004

Fuel level sensor

SEN--006

Water in fuel sensor

SEN--008

Engine coolant temperature sensor

SEN--009A

Engine rpm sensor

SEN--010

Tractor speed sensor

SEN--012

Air filter clogged sensor

SW--003

Full--beam/low--beam headlight switch

SW--005

Power take--off switch (hydraulic version)

SW--005A

Power take--off switch (mechanical version)

SW--006

Operator present switch

SW--007

Engine oil pressure switch

SW--011

Brake oil level switch

SW--020

Work lights switch

SW--021

Four--wheel drive switch

SW--024

Handbrake switch

SW--024A

Parking block switch (NASO)

SW--032

Home / Enter switch

SW--715

Starting switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

ELECTRONIC CONTROL UNIT INPUTS/OUTPUTS (ADIC)

MDQ0166A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

SECTION 55 -- ELECTRICAL SYSTEM Chapter 2 -- STARTING SYSTEM

CONTENTS Section

Description

Page

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Starter and recharging circuit, manual transmissions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 System testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Starter motor Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

TECHNICAL DATA

SPECIFICATIONS

Models Powerstar T4.55, T4.65 and T4.75.

Starter motor Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Iskra AZE4194

Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.2

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

8.3

Pinion: Number of teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.175

TORQUE SPECIFICATIONS Nm Starter motor and engine block assembly bolts . . . . . . . . . . . . . . . . . . . .

Casing on starter motor/ground wire side . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid valve wire nuts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Box nuts on starter motor side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid valve retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

DESCRIPTION AND OPERATION

All systems consist of an ignition key--switch, heavy--duty wiring, a starter motor with an electromagnet, a starter relay, gearbox neutral switch and a switch on the PTO actuator. These are the basic circuit components used on manual transmissions to ensure the engine can be started only under the proper conditions.

There are two categories of gearboxes: with synchronized mechanical shuttle (8X8 and 12 X12), one with two ranges and one with three ranges, with the variant of the creeper unit (12X12 and 20X20); with mechanically operated hydraulic shuttle (8X8 and 12 X12), one, again with two ranges and one with three ranges, with the variant of the creeper unit (12X12 and 20X20): the starting circuit is illustrated on page 4.

Only one starter motor available with rated power 3.2 kW, for F5A engines mounted on all models. This motor has four poles, four brushes with integrated electromagnet and positive mesh engagement control.

The electromagnet consists of two parallel--connected windings. The low resistance intake winding is grounded via the engine, whilst the high resistance hold winding is grounded via the -electromagnet body.

a series of contacts in order to directly power--up all four field coils, thereby supplying full power to the starter motor.

At this stage, one end of the intake coil is connected to the positive battery pole through the starter switch, whilst the other end is connected to the positive battery pole through the solenoid valve contacts. In this manner the intake coil is bypassed, without absorbing power, and the hold coil exclusively maintains the electromagnet plunger in position.

The starter motor includes a series of contacts and a two--part electromagnet plunger that totally closes the contacts, even if the pinion teeth are not perfectly in line with those of the crown wheel. When this happens, a clutch spring compresses the pinion, forcing it to engage completely as soon as the starter motor begins to turn over.

When the key--switch is released, power to the electromagnet and motor is cut off. The electromagnet return spring, acting on the adjustable joint mechanism, frees the driving pinion from the gear and re--opens the solenoid valve contacts.

A roller--type clutch mechanism is incorporated in the driving pinion unit. This prevents the pinion from overspeeding if it remains engaged in the flywheel crown wheel after the engine has started.

When the key--switch contact is turned on with the clutch disengaged and the power take--off disengaged the electromagnet coils are energized and the plunger is magnetically drawn into the electromagnet. This movement, transmitted by an adjustable joint mechanism, makes the driving pinion engage the flywheel rim gear. When the pinion makes contact with the rim gear, the plunger closes

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

STARTER AND RECHARGING CIRCUIT ALT--001

Alternator

BAT--001

Battery

C--001

Engine cable main connector

C--003

Transmission cable main connector

C--005B

Power take--off switch extension cable connector (mechanical version)

C--009

Instrument panel connector

C--010

Instrument panel connector

CB--001

Battery cut--out switch

F--001GH

Grid Heater 125A mega--fuse

F--M004

Deck service 50A mega fuse

M--004

Starter motor

MOD--001A

Fusemodul

MOD--001B

MOD--3/4

F--8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F--10

(+12V from pin 15--SW--715) Pneumatic seat

F--11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

Relay module RLY--MR1

Starting

RLY--27

Starting safety

Power fuse module F--M004

Deck service 50A mega fuse

RES--001

Grid heater element

SEN--002

Gearbox neutral sensor

SEN--004A

KSB sensor

SEN--008

Engine coolant temperature sensor

SOL--005

Engine stop solenoid

SW--715

Starting switch

SW--005A

Power take--off switch (mechanical version)

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

MDQ0167A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

TROUBLESHOOTING The engine does not turn over when the starter key is turned, gearbox in neutral and power take--off disengaged.

Is the battery fully charged?

YES

Charge or replace the battery, check the battery cut--out too. Does the engine turn properly? NO

Check the starting circuit wiring. Are all connections tightened, is the battery correctly grounded, are there any broken or frayed wires present, which could cause a short circuit?

YES

Reconnect the wiring.

Is the engine seized?

YES

Find the cause of engine failure.

Turn the starter key: there is a +12Volt reading at the electromagnet input (2.5 red--black lead).

YES

You can hear the electromagnet trip NO

Check the power take--off switch and the gearbox neutral switch: are the wires connected? Are the switches efficient?

YES

The coils or brushes are probably faulty, or mechanically damaged

Reconnect the wires to the switch, replace the switches if necessary.

Check the fuse F8 (5A), replace it if this is the case and repair the system if necessary.

YES

With the power take--off disengaged and the gearbox in neutral are there +12 Volts at pin 86 (0.75 grey wire) of relay RLY 27? At pin 30 and 85 (0.75 and 0.50 black wire) of the same relay is there a ground signal? With the above buttons closed at pin 87 (0.75 grey--red wire) is there a ground signal? YES

At pin 87 (2.5 dark blue wire) of the relay RLY MR1 is there +12volt? At its pin 85 (0.75 grey--red wire) is there a ground signal, again with the buttons closed? Can you hear the relay trip? From pin 30 (2.5 red--black wire), do +12 volts come out when turning the key?

Check the fuse F--M004 (50A), replace it if this is the case and repair the system if necessary or replace the relay.

YES

continues

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

continued

Does the instrument panel display light up when the starter key is turned? YES

Check that the battery main power supplies the switch pin +30 of the key, and that on turning the key current leaves pin 15/15B and 50 of the connector.

Check the starter key--switch: if the wire on the switch is OK, replace the switch.

Fuse and relay locations. -- Tractors with no cab. On the left--hand side of the column of the steering wheel remove the panel (1).

1 Underneath the panel there is the fuse box with its cover (1).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

Fuse and relay locations. -- Tractors with cab. On the left--hand mudguard, remove the covering panel (1) secured with the screws.

MDQ0168A

3 Underneath the panel there is the fuse box (1).

MDQ0169A

SYSTEM TESTS STARTING SYSTEM TEST ON TRACTOR To troubleshoot the starting system simply and rapidly with conclusive results, use a battery/starter tester (high discharge rate tester) with incorporated 0 to 20 V voltmeter and 0 to 500 A ammeter. When using testing devices, follow test procedures recommended by the manufacturer. If testing devices are not available, carry out the following procedure using a standard 0 to 20 V voltmeter and a 0 to 500 A ammeter to check correct starter motor operation, without removing it from the engine. Before the test: •

Check that the battery is fully charged.

•

Check the condition of all the starting system wiring (no damaged or frayed wires, no loose connections).

•

Check that the engine is not seized.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 CURRENT ABSORBED ON THE STARTER MOTOR CIRCUIT (Fig. 5) 1. Disconnect the battery (3) ground cable (negative). 2. Disconnect the positive battery cable from the starter electromagnet (5). Connect the positive lead of an ammeter (1) to the positive battery terminal and the negative lead to the electromagnet input terminal (5).

3. Reconnect the ground wire (negative) to the battery negative terminal (3). 4. Connect the positive voltmeter point (2) to the positive battery terminal clamp and the negative to the negative battery terminal clamp.

26630

5 5. Disconnect the injection pump closing solenoid valve wire. 6. Run the engine and note voltmeter and ammeter readings. Voltage must remain constantly around 12 V with an absorption value of 250 to 300 amp. •

If the absorption value corresponds with the technical data, the starter motor (4) is working correctly. If voltage drops during the test, carry out the “Starting system circuit resistance” test (see the relative heading).

•

If the absorption value exceeds that of the technical data, check the circuit as described below. If the starting system circuit tests are satisfactory, then the starter motor is faulty and will need to be removed in order to identify the cause.

•

If the current absorption value is lower than that of the technical data, then the starter motor is faulty and will need to be removed in order to identify the cause.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

STARTING SYSTEM CIRCUIT RESISTANCE (VOLTAGE DROP) (Fig. 6) If the voltage absorption value is too high, check the individual circuit components to find the cause of the voltage drop. IMPORTANT: Disconnect the fuel injection pump shut--off solenoid valve wire.

Battery positive cable

1. Connect the positive voltmeter point (1) to the positive battery terminal clamp (2).

2. Connect the negative lead on the voltmeter to the starter motor electromagnet terminal (3). 3. Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the cable connections. Re--check the voltage and, if the value is still too high, replace the cable.

26631

6 Starter motor ground connections

1. Connect the positive lead on the voltmeter (1) to the starter motor casing (2). 2. Connect the negative lead on the voltmeter to the engine block (3). 3. Run the engine and check the voltmeter readings. If the value exceeds 0.2 V, check the ground connections between the starter motor flange and the engine rear cover.

26632

7 Battery ground lead (Fig. 8)

1. Connect the positive lead on the voltmeter (1) to the engine block (2).

2. Connect the negative lead on the voltmeter to the negative terminal on the battery (3). 3. Run the engine and check the voltmeter readings. If voltage exceeds 0.2 V, check and tighten the ground cable connections. Re--check the voltage and, if the value is still too high, replace the ground cable. 26633

3 8

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

STARTER MOTOR REMOVAL--INSTALLATION

1. Raise the bonnet

MDQ0169A

9 2. Take out the bolt (1). 3. Remove the guard (2)

MDQ0170A

4. Disconnect the wire (1) from the starting relay (RLY--MR1). 5. Unscrew the nut (2) retaining the cables: -- connection of battery (4), -- charge of alternator (3), 6. Unscrew the starter motor assembly bolts (5) and extract the motor.

7. To reassemble the starter motor, carry out the removal operations in reverse order. MDQ0171A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

STARTER MOTOR COMPONENTS

MMN1096A 12 1. Control side support.

6. Stator.

2. Coupling.

7. Rotor.

3. Lever.

8. Brush holder.

4. Reduction unit.

9. Switch cover.

5. Electromagnet.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 DISASSEMBLY 1. Position the starter motor in a vice with padded jaws. 2. Disconnect the biggest braided cable that connects the field coils casing with the electromagnet. 3. Remove the three screws from the front casing and extract the electromagnet. Remember that the plunger remains connected to the control lever. 4. Remove the electromagnet plunger by raising and releasing it from the control lever. 5. Remove the two nuts from the rear casing and the two screws that secure the rear cover and the brush plate to the casing. Remove the â&#x20AC;&#x153;Câ&#x20AC;? clamp and the armature shaft end--float adjustment shims, leaving the brush gear on the switch. Remove the fine metal washer from the switch side of the armature. 6. At this stage of the procedure, check the brushes and the switch. Check that the brushes are not stuck together and, if necessary, clean both the brushes and the respective channels with a cloth soaked in kerosene. Also check that the brushes are not worn. If the minimum length is less than that shown in the technical data, the starter motor will need to be replaced.

NOTE: The brushes cannot be serviced separately. They are welded to their support and will not be changed for the whole operating life of the starter motor.

7. Extract the motor casing from the armature and the bracket on the control side. 8. Extract the control lever knuckle pin from the control side of the casing. 9. Remove the circlip that holds the control unit and the inner plate to the armature shaft, by first removing the circlip retaining collar perpendicularly using a suitably sized piece of piping. Then lever the circlip from the groove. 10. Extract the armature and control unit.

REASSEMBLY 1. To reassemble the starter motor, carry out the disassembly operations in reverse order. Before reassembly, check the armature axial end--float and test the starter motor (without load). Checking armature end float 1. Position the starter motor in a vice with padded jaws and connect a dial gauge to the flange on the control side of the casing. Position the dial gauge pointer on the end of the armature shaft. 2. Push the armature fully forward and zero--set the dial gauge. Push the armature fully back and note the reading on the instrument. 3. Readings must fall within the limits specified in the technical information table. If the value is higher, check the armature and brush plate are not worn. Replace worn parts and, if necessary, check the end float again.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEM Chapter 3 -- CHARGING SYSTEM CONTENTS Section

Description

Page

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Alternator Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Alternator components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 TECHNICAL DATA

SPECIFICATIONS

Models Powerstar T4.55, T4.65 and T4.75.

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

Iskra AAK4314

Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounded negative

Nominal voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Maximum Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rpm

13000

Maximum output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

120

Energizing circuit resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

â&#x201E;¦

2.7

TORQUE SPECIFICATIONS

Nm Alternator fastening bolts

5.5

Pulley retaining nut

Rectifier attaching screws

4.0

Brush box and regulator screws

2.7

Terminal nuts

2.7

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

380001268

Belt tension meter.

DESCRIPTION AND OPERATION DESCRIPTION OF THE ALTERNATOR An Iskra--type 120 A external cooling fan alternator is fitted on all models. Stator winding is ventilated with an air conducting diaphragm in the support on the rectifier bridge side and peripheral openings in the support on the control side. The alternator, installed on the right--hand side of the engine, is operated by a pulley and a driving belt. Alternators are fitted with a built--in regulator. 1.

Alternator speed connection (terminal W) not used.

Alternator charge indicator connection (D+ terminal).

Battery connection (B+ terminal).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

2 Alternator charging circuit 1. 2.

Starter switch Alternator charge LED

5. Alternator B+ Battery connector

3. 4.

Battery Alternator electronic voltage regulation circuit.

D+ Alternator charge indicator W Not used

ALTERNATOR FUNCTIONING Refer to figure 2. When the starter key is turned, low current passes from the battery through the rotor field wiring. The circuit closes between the LED indicating the charge, the alternator D+ terminal, the rotor field winding, the alternator regulator and earth (ground). At this point the LED illuminates and the rotor is partially magnetized. When the engine is started and the partially magnetised rotor revolves within the stator windings a three--phase alternating current is generated. A constant quantity of this current is transformed into direct current by three field diodes incorporated in the rectifier unit.

84419869A - 06 - 2011

The direct current is then reintroduced into the circuit to increase current flow through the rotor field winding. This action causes a constant increase in the rotor magnetic field, together with a rapid increase of current and voltage output. As the generated voltage output (reflected by D+ terminal) increases, the LED intensity decreases and when the voltage at the D+ terminal equals that on the battery side of the warning light, the light goes out. Voltage continues to increase until it reaches the pre--stabilised regulated voltage level. If the driving belt breaks, there will be no voltage accumulation in the alternator. The charge warning light will remain on -- indicating the presence of a fault.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SYSTEM TESTING AND TROUBLESHOOTING PRECAUTIONS DURING THE OPERATION To avoid damage to the components of the alternator charging system, the following precautions must be observed: •

NEVER MAKE OR BREAK any charging circuit connection, including the battery, when the engine is running.

•

NEVER SHORT CIRCUIT the alternator positive terminal to check if it is working.

•

ALWAYS DISCONNECT battery cables when re--charging the battery on the tractor with a battery charger.

•

ALWAYS CHECK battery polarity when installing a battery or using a supplementary battery to start the engine.

•

DO NOT SHORT CIRCUIT regulator input/output terminals whilst the alternator is working.

•

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

PRELIMINARY CHECKS Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections, making sure they are correctly tightened. 1. CHECK BATTERY Check all battery elements with a densimeter. The battery must be at least 70% charged and efficient. 2. DRIVING BELT CHECK Inspect the alternator driving belt and pulley, making sure that they are both clean and in good condition, with no traces of oil or grease. Check the alternator driving belt tension regularly. If the belt tension is insufficient, check the belt tensioner as indicated below.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

6 --

BELT TENSIONING

A. Loosen the screw in the slot of the belt tensioner (3) and that of the alternator pivot (1), the belt tensioner tie--rod / alternator fastening screw (2), then loosen the lock nut of the screw at the end of the belt tensioner (4).

2 3

1 MDQ0172A

3 The drive belt is tensioned as follows: B. Tighten the screw of the belt tensioner tie--rod to reset the lower slot of the tie--rod, in practice it must be pulled fully, as it is an elastic belt.

5 4

C. Tighten the lock nut of the screw (5, fig. 3), tighten the other three screws of the belt tensioner tie--rod (1, 2 and 3, fig. 3).

Alternator pulley.

Coolant pump.

Alternator.

Fan hub.

Belt tensioner tie--rod.

3 2

MDQ0173A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

ALTERNATOR Removal -- Installation IMPORTANT: Before disconnecting the alternator wires, make sure that the starter key is in the OFF position.

1. Raise the bonnet

MDQ0170A

2. Loosen the screw retaining the lower part of the alternator (1), loosen the screw retaining the belt tensioner to the alternator (2) and the screw retaining the belt tensioner to the crankcase (3). 3. From the screw of the tensioner (4) unscrew the lock nut and loosen the screw so as to extract the belt. 4. Remove the alternator taking out the fixing screws (1 and 2). 6

5. For reassembly, carry out the operations described above in reverse order.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

ALTERNATOR COMPONENTS 1.

Pulley

10. Terminals: B+, D+ and W

Bearing

11. Gaskets

Cooling fan

12. Capacitor

Front support plate

13. Rear bearing

Stator

14. Brush holder

Rotor

15. Brushes

Rear support plate

16. Rubber seal

Rectifier

17. Retaining ring

Cover

18. Felt gasket

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 -- ELECTRICAL SYSTEM Chapter 4 -- BATTERY CONTENTS Section

Description

Page

Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery testing and charging procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

84419869A -- 06 -- 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

TECHNICAL DATA Models T4.55, T4.65 and T4.75.

SPECIFICATIONS

Without cab* 88 Ah

With cab 100 Ah

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cold start amperage . . . . . . . . . . . . . . . . . . . . . .

C.C.A

1x730

1x800

Capacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

Negative

Number of elements . . . . . . . . . . . . . . . . . . . . . . Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Grounding terminal . . . . . . . . . . . . . . . . . . . . . . . *

For ISO markets as a variant there is the possibility of fitting the 100Ah battery.

DESCRIPTION AND OPERATION Both types of batteries maintenance--free”.

are

“sealed

and

The battery is set in front of the radiator, inside the front axle support compartment. NOTE: “Maintenance--free” means that the battery does not leak electrolyte in normal conditions of use. Leaks may occur if the battery is charged over 14.4 V. This causes the liquid to boil as a result of the gas formed whilst the battery is fully charging. This event may be caused by a charging system fault, quick recharging or topping up. The four main functions of a battery are: • to supply a source of electric energy for starting, switching on and running the instruments. •

to control the electrical system.

•

to supply electricity when the power required is higher than that produced by the alternator.

84419869A -- 06 -- 2011

•

to support inactive loads from the radio and the microprocessor memory.

Each element of the battery consists of positive and negative plates, positioned alternatively one next to the other. Each positive plate is separated from the adjacent negative plate by means of a porous insulating spacer. If one of the positive plates touches a negative plate in the element, the element will short--circuit and be irreversibly damaged. All of the positive plates are welded to a bar and form a positive terminal, whereas all of the negative plates are welded to a similar bar and form a negative terminal. Each positive plate consists of a lead grid with lead peroxide pasted to the grid holes. The negative plates consist of a lead grid with lead sponge pasted to the grid holes. The plates are covered by electrolyte formed by a diluted sulphuric acid solution. The battery casing is made of polypropylene.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

REMOVAL AND INSTALLATION Battery Located on top of the front axle support. To access the battery (on both versions), proceed as follows: 1. Raise the bonnet. 2. Disconnect the ground lead from the tractor frame and secure out of the way. 3. Loosen the bolts on both terminals and disconnect the negative and positive cables from the battery (1), making sure that they do not touch the battery. 4. Using the handles, fitted on both ends of the battery, lift and remove the battery from its housing.

MMR0020A

INSTALLATION Applicable to all types of battery 1. To re--install the battery, reverse the removal procedure, with the following precautions: •

Make sure that the battery is clean and there are no traces of electrolyte leakage, also check that the breather covers are correctly installed. Spread petrolatum (e.g.: vaseline); do not use traditional lubricants as they favour electrolytic corrosion.

•

Make sure that the battery housing and support are clean without objects (stones, etc.) which could pierce the battery casing.

•

Make sure that the battery terminal polarity is correct and that the terminal connections are not too tight.

•

The radio and the clock will lose their data stored in memory and will need to be reprogrammed. Electronic control units and microprocessors -when installed -- will not lose stored data, as electronic stress and transmission control calibration are not involved in this operation.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

BATTERIES TESTING AND CHARGING PROCEDURES The tractor ranges use two different types of battery (100Ah) that require different charging procedures. NOTE: All claims under warranty concerning the batteries must indicate the battery date code. Batteries type A NOTE: The following batteries are used only in production. They can be identified by: --

The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares).

The position of the production date code. The date code is on the bottom right--hand side of the positive terminal.

Example of date code: 14L 7 044 14 L = Production plant 7 = Year (2007) 044 = Progressive number

2 Batteries type B NOTE: The following batteries are used in production and in the spare parts service for changing batteries. They can be identified by: --

The part number hot stamped on the top of the battery casing or given on the label (even though necessarily at times these do not correspond to the numbers used as spares).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 --

The position of the production date code. The date code is on the bottom right--hand side of the positive terminal.

Example of date code: 7C CW06 7 = Year (2007) Production plant C = Month (February) A = December, B =January, C = February, D = March, E = April, F = May, G = June, H = July, J = August, K = September, L = October, M = November. CW06= Production plant

NOTE: Refer to the work flow diagrams on the following pages to check, test and charge the batteries.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

1. -- Flow chart for battery maintenance: Test Instructions

Dry battery suspected of being flat Make a visual check (see the flowchart 2). Has the problem been identified?

YES

Correct the problem as required

YES

The battery must be fully charged before proceeding to the high charge test.

Test the charge status [specific gravity or open circuit voltage test (*). See flow charts 3 and 4] NO

Perform a state of high charge test (see flowchart 5). Is the measured voltage less than 9.6 volts? NO

YES

The battery power level is inadequate and its charge must be tested before being fully charged.

The battery has adequate power and can be charged normally.

(*) The charge status can be tested using a hydrometer and a voltmeter. The most effective method to determine the battery charge status consists in measuring the specific gravity of the electrolyte in the battery and, where possible, this is preferable to the open circuit voltage method.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

2. -- Battery test procedure: Visual check

Remove the battery cover (where fitted)

Identify the battery size, part number and supplier.

Is the battery casing cracked or are the battery poles loose?

YES

A cracked casing or loose/broken poles can cause electrolyte leakage, then it is necessary to replace the battery.

YES

Clean/tighten/replace/repair as required and continue to test the battery.

Are the cables and connections damaged, dirty or loose? NO

Are the battery terminals corroded?

YES

The battery connector or terminal is loose.

Clean the terminals using water and sodium bicarbonate (baking soda). A wire brush may be required to remove heavy corrosion. Dry the battery and continue with the test.

YES

Tighten, if necessary, and continue with the battery test.

YES

Top--up using distilled or de--mineralised water. Do not overfill and do not use tap water or rain water. Continue with the battery test.

YES

This could be due to a high level of battery self--discharge. Correct the cause of the problem, then replace the battery.

Check the electrolyte level. The electrolyte should be around 17 mm above the plates. Is the electrolyte level low in any of the cells? NO

Using a hydrometer, check whether the electrolyte is excessively cloudy or discoloured (discolouring could be due to overfilling or vibration). Is it discoloured or cloudy? NO

Continue with the state of charge test (*). (*) The charge status can be tested using a hydrometer and a voltmeter. The most effective method to determine the battery charge status consists in measuring the specific gravity of the electrolyte in the battery and, where possible, this is preferable to the open circuit voltage method.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

3. -- Battery test procedure: specific gravity (charge status test). NOTE: State of charge tests are used to determine if there is sufficient charge in the battery to perform a high charge test, but does NOT verify the capacity of a battery to start the engine.

If the electrolyte level is too low, add distilled water up to the recommended level of 17 mm above the plates in order to carry out the test. Charge the battery for two hours, then leave it disconnected for 15 minutes before the test. (Refer to the charge flow chart 6).

Taking special care no electrolyte comes out, shake the battery to mix the electrolyte in the battery cells. Take the caps off the holes and draw up the electrolyte with a hydrometer. Note the specific gravity (SG) of each cell, starting with the cell nearest the positive terminal of the battery.

Adjust the hydrometer readings for all the temperature variations (+/-- 0.004 SG for every +/-- 5.5 Â°C change in hydrometer temperature).

Adjust the SG values for each cell. Is there a variance greater than 0.025 between the cells?

YES

If one or more battery cells are defective, replace the battery.

Refer to the following table to determine the state of charge.

STATE OF CHARGE

SG CORRECT AT 15_ _C

SG CORRECT AT 25_ _C

VOLTAGE OF BATTERY AVERAGE

100%

1.295

1.287

12.60

75%

1.253

1.246

12.40

50%

1.217

1.210

12.20

25%

1.117

1.170

12.00

DISCHARGED

1.137

1.130

11.80

NOTE: SG = Specific gravity.

84419869A -- 06 -- 2011

FOLLOWING PHASES Continue with the high charge test. Fully recharge the battery before performing a high charge test. (Refer to flow chart 6). Battery discharged. A slow charge is necessary. (Refer to flow chart 6).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

4. -- Battery test procedure: open circuit voltage. (charge status test).

To eliminate any surface charge of the battery, switch on the vehicleâ&#x20AC;&#x2122;s headlights for a minute, then turn them off and leave the vehicle for 5 minutes.

Measure the open circuit voltage by connecting a digital voltmeter across the battery terminals.

Refer to the following table to determine the state of charge of the battery.

VOLTAGES

STATE OF CHARGE

FOLLOWING PHASES

Greater than 12.4 volts

Greater than 75%

Continue with the high charge test refer to flow chart 5).

12.0 -- 12.4 volts

25% Ăˇ 75%

Charge the battery fully (refer to the charge work flow chart 6) before running a high charge test (refer to flow chart 5).

Less than 12 volts

less than 25%

Battery discharged. A slow charge is necessary. (Refer to the charge flow chart 6).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

5. -- Battery test procedure: high discharge test.

Check that the battery charge status is at least 75% (12.4 volts)

Determine the nominal battery power as stated on the label (800CCA or 960CCA).

Connect the high charge tester to the battery terminals, on the correct poles.

Charge the battery to a current equal to three times the nominal power Amp--h (Ah) or half the nominal power, in amps, needed for cold starting (CCA).

To eliminate the surface charge, connect the tester to the battery for 15 seconds at the specific discharge current, then disconnect and leave cut off for 5 minutes.

Apply the charge for no longer than 15 seconds and note the voltmeter reading.

Is the voltage on the terminal less tan 9.6 volts? NO

The battery has adequate power and accepts the normal charge, if necessary, (refer to the charge flow chart 6), or it can be put back into operation.

84419869A -- 06 -- 2011

YES

The battery has adequate power and must be charge tested before being completely charged and tested again (refer to flow chart 7).

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

6. -- Battery charge flow chart: Charge Instructions.

Before charging the battery, check that the level of electrolyte is adequate. Clean the battery casing and cell covers with diluted ammonia and hot water. Clean the battery terminals if necessary.

If the battery has not passed the high charge test, carry out the permissible charge test (see flow chart 7) to determine whether the battery can take the charge.

Charge the battery following the “standard” method or ”slow charge” for excessively discharged/sulphated batteries (*) (the charge procedures recommended by manufacturers are given in flow charts 8 and 9).

After charging, run the high discharge test (see flow chart 5) to check that battery performance is sufficient.

(*) A battery that has been discharged too much, that is with a charge status equal to or less than 25%, for an extended length of time becomes sulphated. The higher the level of sulphation and the more likely it is that the battery will not take the charge and must be replaced.

84419869A -- 06 -- 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

7. -- Battery charge work flow chart: permissible charge test.

This test is for batteries that have not passed the high charge test. Charge the battery with a high rate charger set to 40A for 2 -- 3 minutes and note the battery voltage.

Is the voltage below 11 volt or above 16 volt? NO

The battery probably takes a full charge. Refer to the manufacturerâ&#x20AC;&#x2122;s charging procedures (flow chart 8 and 9).

84419869A -- 06 -- 2011

YES

The battery is probably sulphated or defective and must be replaced.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

8. -- Battery charge work flow chart: procedure for charging A--type batteries.

Check that the battery is TYPE A by checking its identification label.

Check that the battery voltage is less than 12.6 volts by testing the charge status (flow chart 3 or 4).

Refer to the following table for the recommended charge currents.

BATTERY VOLTAGE

RECHARGE CURRENT

RECHARGE TIME

RECHARGE VOLTAGE

Volts

Amps

Hours

Volts

12.2 รท 12.6

10% of the nominal value Ahr

15.9 รท 16.2

Below 12.2

10% of the nominal value Ahr

15.9 รท 16.2

Check the battery voltage after 24 hours to make sure the battery is fully charged (equal to or greater than 12.6 volts).

NOTE: Check that the charger used to charge the A- Type battery does not have a capacity greater than 16.2 volts, otherwise the battery could get damaged.

84419869A -- 06 -- 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

9. -- Battery charge work flow chart: procedure for charging B--type batteries.

Check that the battery is TYPE B by checking its identification label.

Check that the battery voltage is less than 12.6 volts by testing the charge status (flow chart 3 or 4).

Refer to the following table for the recommended charge currents.

BATTERY VOLTAGE

RECHARGE CURRENT

RECHARGE TIME

RECHARGE VOLTAGE

Volts

Amps

Hours

Volts

12.45 ÷ 12.65

10% of the nominal value Ahr

14.7 ÷ 14.8

12.20 ÷ 12.44

10% of the nominal value Ahr

14.7 ÷ 14.8

Below 12.2

Sulphate crystals have formed on the electrodes, it is therefore necessary to perform the two separate charging sequences described below

First recharge sequence

1 (or the lowest possible setting)

14.7 ÷ 14.8

Second recharge sequence

10% of the nominal value Ahr

14.7 ÷ 14.8

Check the battery voltage after 24 hours to make sure the battery is fully charged (equal to or greater than 12.6 volts).

NOTE: Check that the charger used to charge the B- Type battery is no greater than 14.8 volts, otherwise the battery could get damaged.

84419869A -- 06 -- 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 -- ELECTRICAL SYSTEM Chapter 5 -- ELECTRICAL CIRCUITS CONTENTS Description

Page

Maxi power fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Version without cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Version with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Layout of cab--version fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Version without cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Version with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Layout of fuses in the cab (Standard / Full optional version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Battery cut--out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Electronic modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Main Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Ground points identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 How to use the wiring diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Electric wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Wiring diagram components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Electric diagrams components (gathered in groups with descriptive order . . . . . . . . . . . . . . . . . . . . . . . . . . 48 List of tables of new utility series system without cab (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 List of tables of new utility series system without cab (Full Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Electric circuits components for version without cab (with the code in ascending order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 List of tables of new utility series system with cab (Standard) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 List of tables of new utility series system with cab (Full Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Electric circuits components for version with cab (with the code in ascending order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

MAXI POWER FUSES The maxi power fuses box Layout of power fuses for tractor with cab For tractor with battery cut--out Right side of engine, under the bonnet, at the height of the fan there is a box (1) with two 50 A fuses, one for the tractor services and the other for the cab. Obviously for tractors without a cab instead of a box with two fuse carriers there will be one with a single fuse. For tractor without battery cut--out Left side of engine, under the bonnet, at the height of the fan there is a box with two 50 A fuses, one for the tractor services and the other for the cab. Obviously for tractors without a cab instead of a box with two fuse carriers there will be one with a single fuse.

MDQ0175A

VERSION WITHOUT CAB ISO “Standard” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

(50A)

SW--715 pin. 15A and 15B ⇒

F--4, F--5, F--9, F--11, F--12, F--13, F--15 and F27

Pin 50

F--8

⇒

Socket 8 A ⇒ F--3 ⇒ F--1, F--2, F--6, F--7, F--14, F--20, F--24 and F--26 ⇒ RLY--MR1 Starting M--004

Side lights ⇒ RLY--2 ⇒ ALT--001 ⇒ F--001GH

F--1m (5A)

⇒ ⇒

F--16, F--17 and F--18 RLY--001GH grid heater circuit

Safety and control panel memory (with battery cut--out)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

ISO “Full optional” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

SW--715_30_50

(50A)

pin. 15A and 15B ⇒

F--4, F--5, F--9, F--11, F--12, F--13, F--15, F21, F--25 F27

Pin 50

⇒

Socket 8 A

⇒ F--3 ⇒ F--31

Socket 25 A

⇒ F--1, F--2, F--6, F--7, F--14, F--20, F--24 and F--26 ⇒ RLY--MR1 Starting Side lights ⇒ RLY--2 ⇒ F--16, F--17 and F--18 M--004

⇒ ALT--001 ⇒ F--001GH

F--1m (5A)

⇒

RLY--001GH grid heater circuit

Safety and control panel memory (with battery cut--out)

NASO “Standard” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

(50A)

⇒ F--3 ⇒ F--31

SW--715_30_50 pin. 15A and 15B ⇒

F--4, F--5, F--9, F--11, F--12, F--13, F--15, and F27

Pin 50

F--8

⇒

Socket 8 A Socket 40 A

⇒ F--1, F--6, F--7, F--20, F--24, and F--31 ⇒ RLY--MR1 Starting Side lights ⇒ RLY--2 ⇒ F--16, F--17 and F--18 M--004

⇒ ALT--001 ⇒ F--001GH

⇒

RLY--001GH grid heater circuit

NASO “Full optional” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒ Pin +30 SW--715_30_50

(50A)

pin. 15A and 15B ⇒

F--4, F--5, F--9, F--11, F--12, F--13, F--15, F--25 and F27

Pin 50

F--8

⇒

Socket 8 A ⇒ F--3 Socket 40 A ⇒ F--31 ⇒ F--1, F--6, F--7, F--20, and F--24

⇒ RLY-MR1

M--004

Starting

⇒ RLY--2 Side lights ⇒ ALT--001 ⇒ F--001GH

⇒ ⇒

F--16, F--17 and F--18 RLY--001GH grid heater circuit

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

4 MODEL WITH CAB

ISO “Standard” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

(50A)

SW--715 pin. 15a and 15B ⇒

F--4, F--5, F--9, F--10, F--11, F--12, F--13, F--15, F--19, F--23 and F--25

Pin 50

F--8

⇒

Socket 8 A ⇒ F--3 ⇒ F--1, F--2, F--6, F--7, F--14, F--20, F--24, F--26 and F--32 ⇒ RLY--MR1 Starting Side lights ⇒ RLY--2 F--M005 ⇒ F--1c, F--2c and F--3c (50A) Power ⇒ RLY--2c M--004

⇒ ALT--001 ⇒ F--001GH

F--1m (5A)

⇒

F--16, F--17 and F--18

⇒

F--5c and F--6c

⇒

RLY--001GH grid heater circuit

Safety and control panel memory (with battery cut--out)

ISO “Full optional” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

(50A)

⇒ F--3 ⇒ F--31

SW--715 pin. 15A and 15B ⇒

F--4, F--5, F--9, F--10, F--11, F--12, F--13, F--15, F--19, F--21, F--23 and F--25

Pin 50

F--8

⇒

Socket 8 A Socket 25 A

⇒ F--1, F--2, F--6, F--7, F--14, F--20, F--24, F--26 and F--32 ⇒ RLY--MR1 Starting Side lights

⇒

F--16, F--17 and F--18

⇒ F--1c, F--2c and F--3c Power ⇒ RLY--2c ⇒ ALT--001 ⇒ F--001GH

⇒ ⇒

F--5c and F--6c

⇒ RLY--2 F--M005 (50A) M--004

F--1m (5A)

RLY--001GH grid heater circuit

Safety and control panel memory (with battery cut--out)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

NASO “Full optional / Standard” version CIRCUIT PROTECTION SEQUENCE F--M004

⇒

Pin +30

(50A)

⇒ F--3 ⇒ F--31

SW--715_30_50 pin. 15 and 15B

⇒

F--4, F--5, F--9, F--10, F--11, F--12, F--13, F--15, F--19, F--23 and F--25

Pin 50

⇒

F--8

Socket 8 A Socket 25 A

⇒ F--1, F--3, F--6, F--7, F--14, F--20, F--24, F--26 and F--32 ⇒ RLY--MR1 Starting Side lights ⇒ RLY--2 ⇒ F--16, F--17 and F--18 SW--003 Full--beam/low--beam headlight switch ⇒ F--003 F--M005 ⇒ F--1c, F--2c and F--3c (50A) Power ⇒ RLY--2c ⇒ F--5c and F--6c M--004

⇒ ALT--001 ⇒ F--001GH

⇒

RLY--001GH grid heater circuit

POWER FUSES Location of fuses and relays on tractors without a cab. On the left--hand side of the column of the steering wheel remove the panel (1).

5 Underneath the panel there is the fuse box with its cover (1).

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Location of fuses and relays on tractors with a cab. On the left--hand mudguard, remove the covering panel (1) secured with the screws.

MDQ0168A

7 Underneath the panel there is the fuse box (1).

MDQ0169A

8 On the NASO version the fuse F003 40A contained in MOD--003 is by the side of the box (1)

MDQ0176A

9 On the right--hand pillar, where there are the housing of the air conditioning controls and cab switches, on the top, under the radio housing, under the panel, there is the cab fuse box (1).

MDQ0179A

10 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version without cab “Standard -- Full Optional” ISO -- NASO)

11 Fuse box explanatory label.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version without cab, “ISO Standard”)

12 MOD--001A

Fuse module

MOD--001B

Relay module

MOD--001C

Fuse and Relay module

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses ISO STANDARD VERSION Fuse Module - MOD- 1A Fuses

Amps

CIRCUITS

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

(+12V from F--M004) Hazard lights switch

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

F10

F11

7.5

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

(+12V from F--M004) Parking brake switch

F15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting CAL switch

F17

7.5

(+12V from pin 87--RLY--2) Front left and rear right light, backlighting switches

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

Not used

F20

(+12V from F--M004) Instrument panel power supply

F21

Not used

F22

Not used

F23

Not used

F24

F25

F26

7.5

(+12V from F--M004) Rotating beacon switch

F27

(+12V from pin 15--SW--715) Swivel lights switch

F28

Not used

F29

Not used

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop Not used

(+12V from F--M004) Cigar lighter Not used

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

CIRCUITS

F30

Not used

F31

Not used

F32

Not used

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Not used

RLY- 27

RLY- 28

Starting safety Not used

Fuse and Relay module - MOD- 1C Fuses

Amps

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, backlighting switches

RLY- 3

Main beam headlights

RLY- 4

Not used

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

84419869A - 06 - 2011

CIRCUITS

Brake lights Not used

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version without cab, “ISO Full Optional”)

13 MOD--001A

Fuse module

MOD--001B

Relay module

MOD--001C

Fuse and Relay module

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

12 Fuses

ISO FULL OPTIONAL VERSION Fuse Module - MOD- 1A Fuses

Amps

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

(+12V from F--M004) Hazard lights switch

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

F10

F11

7.5

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

(+12V from F--M004) Parking brake switch

F15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting CAL switch

F17

7.5

(+12V from pin 87--RLY--2) Front left and rear right light, backlighting switches

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

Not used

F20

(+12V from F--M004) Instrument panel power supply

F21

(+12V from pin 15--SW--715) 3rd distributor splitter circuit

F22

Not used

F23

Not used

F24

(+12V from F--M004) Cigar lighter

F25

(+12V from pin 15--SW--715) Work light

F26

7.5

(+12V from F--M004) Rotating beacon switch

F27

(+12V from pin 15--SW--715) Swivel lights switch

F28

Not used

F29

Not used

84419869A - 06 - 2011

CIRCUITS

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop Not used

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F30

F31

F32

CIRCUITS Not used (+12V from F--M004) 30A auxiliary socket Not used

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Not used

RLY- 27

RLY- 28

Starting safety Not used

Fuse and Relay module - MOD- 1C Fuses

Amps

CIRCUITS

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, backlighting switches

RLY- 3

Main beam headlights

RLY- 4

3rd distributor splitter circuit

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

CIRCUITS

Brake lights Not used

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version without cab, “NASO Standard”)

14 MOD--001A

Fuse module

MOD--001B

Relay module

MOD--001C

Fuse and Relay module

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses NASO STANDARD VERSION Fuse Module - MOD- 1A Fuses

Amps

CIRCUITS

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

F10

F11

7.5

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

Not used

F15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Rear left light and backlighting CAL switch

F17

7.5

(+12V from pin 87--RLY--2) Rear right light and backlighting switches

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

Not used

F20

(+12V from F--M004) Instrument panel power supply

F21

Not used

F22

Not used

F23

Not used

F24

F25

Not used

F26

Not used

F27

F28

Not used

F29

Not used

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch) Not used

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop Not used

(+12V from F--M004) Cigar lighter

(+12V from pin 15--SW--715) Swivel lights switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F30

F31

F32

CIRCUITS Not used (+12V from F--M004) 40A auxiliary socket Not used

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Not used

RLY- 27

RLY- 28

Starting safety Not used

Fuse and Relay module - MOD- 1C Fuses

Amps

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, backlighting switches

RLY- 3

Main beam headlights

RLY- 4

Not used

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

84419869A - 06 - 2011

CIRCUITS

Brake lights Not used

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version without cab, “NASO Full Optional”)

15 MOD--001A

Fuse module

MOD--001B

Relay module

MOD--001C

Fuse and Relay module

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

18 Fuses

NASO FULL OPTIONAL VERSION Fuse Module - MOD- 1A Fuses

Amps

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

F10

F11

7.5

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

Not used

F15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Rear left light and backlighting CAL switch

F17

7.5

(+12V from pin 87--RLY--2) Rear right light and backlighting switches

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

Not used

F20

(+12V from F--M004) Instrument panel power supply

F21

Not used

F22

Not used

F23

Not used

F24

(+12V from F--M004) Cigar lighter

F25

(+12V from pin 15--SW--715) Work light

F26

F27

F28

Not used

F29

Not used

84419869A - 06 - 2011

CIRCUITS (+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch) Not used

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop Not used

Not used (+12V from pin 15--SW--715) Swivel lights switch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F30

F31

F32

CIRCUITS Not used (+12V from F--M004) 40A auxiliary socket Not used

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Not used

RLY- 27

RLY- 28

Starting safety Not used

Fuse and Relay module - MOD- 1C Fuses

Amps

CIRCUITS

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, backlighting switches

RLY- 3

Main beam headlights

RLY- 4

Not used

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

CIRCUITS

Brake lights Not used

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 LOCATION OF FUSES AND RELAYS (Version with cab “Standard -- Full Optional” ISO -- NASO)

MDQ0180A

16 Fuse box explanatory label.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version with cab, ISO “Standard”)

DANGER If electrical system relays need to be changed, check that correct spare parts are used and that they are fitted in the correct positions. The use of structurally or functionally different relays -- even if interchangeable -- could seriously compromise tractor control with dangerous results. Location of fuses and relays in the main housing

MDQ0181A

17 MOD--001A MOD--001B MOD--001C

Fuse module Relay module Fuse and Relay module

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

22 Fuses

ISO STANDARD VERSION Fuse Module - MOD- 1A Fuses

Amps

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

(+12V from F--M004) Hazard lights switch

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F10

(+12V from pin 15--SW--715) Pneumatic seat

F11

7.5

(+12V from pin 15--SW--715) Starting safety circuit and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

(+12V from F--M004) Parking brake switch

F15

(+12V from F--M004) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting Home / Enter switch

F17

7.5

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches, cab lighting and number plate lights on roof

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F20

(+12V from F--M004) Instrument panel power supply

F21

Not used

F22

Not used

F23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F24

(+12V from F--M004) Cigar lighter

F25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F26

7.5

A/C compressor clutch circuit

84419869A - 06 - 2011

CIRCUITS

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F27

Not used

F28

Not used

F29

Not used

F30

Not used

F31

Not used

F32

CIRCUITS

(+12V from F--M004) Cab ventilation circuit

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Cab ventilation

RLY- 27

Starting safety

RLY- 28

Not used

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuse and Relay module - MOD- 1C Fuses

Amps

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

Dipped beam headlights

RLY- 4

Not used

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

84419869A - 06 - 2011

CIRCUITS

Brake lights A/C compressor clutch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version with cab, ISO “Full Optional”)

---

Supplementary control valves splitter Battery cut--out

Location of fuses and relays in the main housing

MDQ0182A

18 MOD--001A MOD--001B MOD--001C

Fuse module Relay module Fuse and Relay module

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

26 Fuses

ISO FULL OPTIONAL VERSION Fuse Module - MOD- 1A Fuses

Amps

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

(+12V from F--M004) Hazard lights switch

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Hazard lights switch

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 50--SW--715) Starting and starting detection line for the instrument panel

7.5

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F10

(+12V from pin 15--SW--715) Pneumatic seat

F11

7.5

(+12V from pin 15--SW--715) Starting safety circuit and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

(+12V from F--M004) Parking brake switch

F15

(+12V from F--M004) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting Home / Enter switch

F17

7.5

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches, cab lighting and number plate lights on roof

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F20

(+12V from F--M004) Instrument panel power supply

F21

(+12V from pin 15--SW--715) 3rd distributor splitter circuit

F22

Not used

F23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F24

(+12V from F--M004) Cigar lighter

F25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F26

7.5

A/C compressor clutch circuit

84419869A - 06 - 2011

CIRCUITS

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F27

Not used

F28

Not used

F29

Not used

F30

Not used

F31

(+12V from F--M004) 25A auxiliary socket

F32

(+12V from F--M004) Cab ventilation circuit

CIRCUITS

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Cab ventilation

RLY- 27

Starting safety

RLY- 28

Not used

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuse and Relay module - MOD- 1C Fuses

Amps

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

Main beam headlights

RLY- 4

3rd distributor splitter circuit

RLY- 5

10/20

Switching dipped beam headlights onto work lights

RLY- 6

10/20

Switching main beam headlights onto work lights

RLY- 7

10/20

Brake lights

RLY- 8

84419869A - 06 - 2011

CIRCUITS

A/C compressor clutch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS (Version with cab, NASO “Full Optional / Standard”)

Air conditioning

Double cigar lighters

Location of fuses and relays in the main housing

MDQ0183A

19 MOD--001A MOD--001B MOD--001C

Fuse module Relay module Fuse and Relay module

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

30 Fuses

NASO STANDARD / FULL OPTIONAL VERSION Fuse Module - MOD- 1A Fuses

Amps

(+12V from F--M004) 8A auxiliary socket

(+12V from pin 15--SW--715) Full--beam/low--beam headlight switch and flasher

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

(+12V from F--M004) Low--beam headlights

(+12V from F--M004) High--beam headlights

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

7.5

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F10

(+12V from pin 15--SW--715) Pneumatic seat

F11

7.5

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F12

(+12V from pin 15--SW--715) Brakes circuit

F13

7.5

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F14

(+12V from F--M004) Parking brake switch

F15

(+12V from F--M004) Diagnostic connector and speed sensor

F16

(+12V from pin 87--RLY--2) Rear left light and backlighting Home/Enter switch

F17

7.5

(+12V from pin 87--RLY--2) Rear right light, work lights switch, backlighting switches and cab lighting

F18

(+12V from pin 87--RLY--2) Seven pole socket

F19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F20

(+12V from F--M004) Instrument panel power supply

F21

Not used

F22

Not used

F23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F24

(+12V from F--M004) Cigar lighter

F25

(+12V from pin 15--SW--715) Windshield wiper circuit

F26

7.5

A/C compressor clutch circuit

84419869A - 06 - 2011

CIRCUITS (+12V from F--M004) Emergency switch and flasher Not used

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuses

Amps

F27

Not used

F28

Not used

F29

Not used

F30

Not used

F31

(+12V from F--M004) 40A auxiliary socket

F32

(+12V from F--M004) Cab ventilation circuit

CIRCUITS

Fuse Module - MOD- 1B Relay

Amps

CIRCUITS

RLY- MR1

Starting

RLY- 25

Not used

RLY- 26

Cab ventilation

RLY- 27

Starting safety

RLY- 28

Not used

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuse - Relay module - MOD- 1B Fuses

Amps

CIRCUITS

F33

Not used

F34

Not used

F35

Not used

F36

Not used

F37

Not used

Relay

Amps

RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

Main beam headlights

RLY- 4

Not used

RLY- 5

Not used

RLY- 6

Not used

RLY- 7

10/20

RLY- 8

CIRCUITS

Brake lights A/C compressor clutch

Location of fuses and relays in the supplementary box (MOD--003) for NASO version

Fuse Module - MOD- 003 Fuses

Amps

F- 003

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CIRCUITS Electronic flasher

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LOCATION OF FUSES AND RELAYS IN THE CAB (Version, “Full optional / Standard”)

MDQ0184A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Fuse and Relay module - MOD- 002

Fuses

Amps

CIRCUITS

F- 1c

Front work lights

F- 2c

Rear work lights

F- 3c

7.5

Rotating beacon and overhead light switch

F- 4c

F- 5c

Fan switch and A/C switch

F- 6c

Rear--window wiper and windshield wiper switch, radio*, windshield wiper (for openable window) and rear--window wiper pump

Relay

Amps

CIRCUITS

RLY- 1c

Rear work lights

RLY- 2c

Power

RLY- 3c

RLY- 4c

Not used

Not used Front work lights

There is no radio on the standard versions.

BATTERY CUT--OUT On ISO markets a mechanical switch is supplied to cut off the battery. Underneath the bonnet, on the left--hand side at the height of the alternator there is the switch (1): with the switch in a horizontal position the battery is not cut off.

MDQ0185A

21 When there is a mechanical battery cut--off, there is the ADIC memory and the operator safety systems that must always be powered (or at least powered for a certain period of time after operating the switch so as to save the data and warn the operator for leaving the vehicle not in safety). Therefore at the switch input there is a connection that leads to a fuse situated just above the switch, by the side of the power fuses.

MDQ0175A

22 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SOCKETS Seven--pin socket (ISO markets). It is (1) at the back on the right of the tractor. With reference to the picture inset, the pin connections (viewed from the front of the socket) are as follows: 1. Left direction indicator. 2. Not used. 3. Ground. 4. Right direction indicator. 5. RH side lights. 6. Brake lights 7. LH side lights.

MDQ0186A

Seven--pin socket (NASO markets). It is (1) at the back on the right of the tractor. With reference to the picture inset, the pin connections (viewed from the front of the socket) are as follows: 1. Ground. 2. RH side lights. 3. Left direction indicator. 4. Brake lights 5. Right direction indicator. 6. LH side lights. 7. Not used. MDQ0187A

For tractors with a cab. 8A power socket. On the right mudguard behind the seat there is an 8A single--pole socket (1). 25A power socket (ISO). On the right mudguard behind the seat there is a 25A socket (2) for ISO markets. 40A power socket (NASO). On the right mudguard behind the seat there is a 40A socket (2) for NASO markets.

MDQ0188A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

For tractors without a cab. 25A power socket (ISO). Behind the tractor on the left of the seven--pole socket there is the 25A socket (1) for ISO markets.

40A power socket (NASO). Behind the tractor on the left of the seven--pole socket there is the 40A socket (1) for NASO markets.

Diagnostic socket For tractors with a cab. On the left mudguard behind the seat there is a diagnostic socket that is used to download software updates for the ADIC dashboard.

MDQ0189A

For tractors without a cab. On the left--hand side of the column of the steering wheel under the panel of the fuse box there is the diagnostic jack that is used to download any software updates for the ADIC dashboard.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

GRID HEATER Underneath the bonnet on the right--hand side there is the relay of the grid heater (1) controlled directly from the dashboard, with the diagram RLY--001GH.

MDQ0190A

Again on the right--hand side of the intake manifold inlet there is the manifold (1) where, on the inside there is the grid heater element, with the diagram RES--001. On the relay power cable there is the power fuse of the grid heater (2), with the diagram F--001GH.

MDQ0191A

ELECTRONIC MODULES Electronic flasher (NASO markets). On the left--hand mudguard, under the panel covering the fuse box there is the connector (1) where the electronic flasher is connected, with the diagram MOD--004A. In the same position, not to the same connector, there is the flasher relay for ISO markets, with the diagram MOD--004.

MDQ0192A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Air--conditioning control unit Underneath the covering of the control console above the heating and air--conditioning unit there is the control unit (1) for the air--conditioning, with the diagram MOD--045. Alongside there is the anti--frost thermostat, with the diagram SEN--044.

MDQ0193A

MAIN CONNECTORS Underneath the bonnet, there is the connector: A the connector between the engine cable and headlights cable, on the diagram C--013C. On the left mudguard remove the panel, secured with screws, covering the fuse box; between this and the cab pillar there are the connectors: B ----

jumper for cab variants: Road lights, on the diagram C--035A. Work lights, on the diagram C--035B. Road lights and work lights, on the diagram C--035C. This is only for ISO markets.

C Cab power connector, on the diagram C--004C. D Connector between the main cable and the cab roof cable, on the diagram C--005C. On the rear left of the tractor, on the left side of the lift upper arms, secured to a bracket, we have: E

Connector between the cab main cable and the transmission cable, on the diagram C--003C.

Raise the bonnet on the left side of the engine, towards the cab, there is: F

Connector between the cab main cable and the mega fuse cable, on the diagram C--002C.

G Connector between the cab main cable and the engine cable, on the diagram C--001C.

NOTE: Notes -- For tractors without a cab the connectors between the various cables are in the same positions as the connectors between the cables in common with the cab.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

MDQ0194A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 GROUND POINTS IDENTIFICATION

MDQ0195A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

MDQ0195A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Behind the tractor on the left side by the side of the lift box there are 2 grounds. A Ground wire connecting the transmission to the cab (see point C). B Transmission wiring harness ground cable, on the diagram GND--002. Behind the tractor on the left--hand side of the cab on the bottom cross member where this is secured to the transmission by means of the plugs, there is a ground wire. C Ground wire connecting the cab to the transmission (see point A). Underneath the covering of the left pillar of the cab, where the left door is hinged, at the top there is a ground wire. D Ground wire of the cab roof wiring, on the diagram GND--003. Underneath the bonnet on the front of the tractor we have the battery ground cable. E

Ground wire that connects the battery negative pole to the machine frame.

On the left mudguard under the panel that covers the fuse box, bolted to the cab pillar we have a ground cable. F

Ground wire of the cab main wiring on the diagram GND--004.

On the left of the operator on the cab pillar on the left of the clutch pedal pivot there is an additional ground wire. G Second ground wire of the cab main wiring on the diagram GND--001. H For tractors without a cab, the main cable has two grounds; one must be attached to the cross member joining the platform to the transmission GND--001. I

The other must be locked under the dashboard on the wall between this compartment and the engine compartment GND--004.

Again for tractors without a cab the 25A (ISO) and 40A (NASO) auxiliary sockets have a ground that must be inserted on the vertical cross member of the platform GND--005, for the 25A socket and GND--001, for the 40A socket.

NOTE: For tractors without a cab, the grounds of the cables compatible with tractors with a cab are inserted at the same points as the tractors with a cab.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

HOW TO USE THE WIRING DIAGRAMS The wiring diagrams in the manual are subdivided by function; the set of all the functions forms the tractorâ&#x20AC;&#x2122;s electric system.

There are a number of guides to help assist in reading and understanding the wiring diagrams.

MPN0946A

36 1. The wiring diagrams (2) are given on the pages on the right; the titles and legends (1) are given on the pages on the left. The title defines the function to which the diagram refers, the key indicates all the components on that specific page of the diagram. 2. The components and connectors are identified by an abbreviation composed of an alphabetical portion and a numerical portion:

the alphabetical portion indicates the type of component (e.g. F indicates a fuse, C indicates a connector, MOD indicates a module, SW indicates a switch, etc.), the numerical portion is a progressive number.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

3. On each connection wire there is an abbreviation that indicates the colour and the cross--section of the wire: the first letter (1) indicates the main colour of the wire, the second letter (2) indicates the colour of the stripe along the wire, the digit (3) indicates the cross--section of the wire in mm 2.

MPM0708A

37 4. To be able to follow the circuit in its entirety, each wire continuing onto a different page of the diagram ends with an arrow and a reference to the page on which it continues or from which it comes. This reference is composed of an abbreviation made up of a number indicating the sheet of the diagram on which the wire continues and one or more letters to indicate the wire on the page being referred to. The following example gives a reference between diagram 1 (1, Fig. 38), for the cab version and diagram 3 (2, Fig. 39).

MPM0699A

MPM0700A

39 5. The termination of the wire on a component is indicated with the symbol of the connection (see the key of symbols used on the diagrams) and the number of the pin on which the wire is connected (1, Fig. 40).

MPM0699A

40 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

CONNECTOR CODE READING The connections on the wiring diagrams are indicated as in the following example. In this example the abbreviation (1) indicates the number of the key of the connection while the second abbreviation (2) indicates the number of the pin of the same connection.

MPM0727A

WIRE COLOUR CODING A

Light Blue

Grey/green

Light blue/black

Grey/yellow

Light blue/yellow

Blue

Light blue/white

Blue/white

Light blue/green

Blue/black

Light blue/red

Blue/red

White

Brown

White/red

Brown/white

White/black

Brown/black

White/blue

Black

White/yellow

Black/purple

Orange

Black/white

Orange/white

Black/red

Orange/black

Red

Orange/blue

Red/yellow

Yellow

Red/black

Yellow/green

Red/green

Yellow/black

Pink

Yellow/red

Pink/black

Yellow/blue

Pink/yellow

Grey

Green

Grey/brown

Green/black

Grey/red

Green/white

Grey/black

Purple

Grey/white

Purple/white

Grey/blue

Purple/black

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SYMBOLS USED IN ELECTRICAL CIRCUITS

Switch

Control switch

Sensor/Switch/Solenoid Valve

Sensor/Switch

Ignition switch

Variable sensor

Motor

Diode

Lighting and indicator lamp Ground Fuse

MPD2703A

84419869A - 06 - 2011

Connection

Rotating beacon power socket

Power fuse

Lamp

Relays

Battery

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

ELECTRICAL CIRCUIT COMPONENTS This section lists a description of the electrical components forming the tractors system. There are two lists, divided in the following order: 1. Descriptive order page 48;

DESCRIPTION

SUFFIX ALT

Alternator

AUD

Audio devices

BAT

Battery

Battery cut--out

C CAP

2. Numerical order page 55 (for tractors without a cab) and page 99 (for tractors with a cab). Below is an explanation of the suffixes related to each component.

Connections Capacitor

Diode

Fuse

GND

Ground

LMP

Lamps

LED

LEDs

MOD

Control units

Engine

RLY

Relay

RES

Resistor

SEN

Sensor

SOL

Solenoid valve

Switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 ELECTRICAL CIRCUIT COMPONENTS (gathered in groups with descriptive order)

DESCRIPTION

CODE

ALTERNATOR Alternator

ALT-001

BATTERY Battery

BAT--001

ELECTRONIC MODULES CONTROL UNITS A/C control module

MOD--045

Memory fuse module

MOD--320

Fusemodul

MOD--001A

Fuse module (Naso)

MOD--003

Fuse and Relay module

MOD--001C

Cab Fuse and Relay module

MOD--002

Power fuse module

MOD--3/4

Electronic flasher module (ISO)

MOD--004

Electronic flasher module (NASO)

MOD--004A

Control panel module

MOD--1_ADIC

Relay module

MOD--001B

CONNECTIONS Fan power supply connector

C--056

Parking block connector (NASO without cab)

C--024B

Power cable connector

C--002

Cab power cable connector

C--004

Memory cable connector to be fitted when there is a battery cut--out

C--001E

Power take--off switch extension cable connector (mechanical version)

C--005B

Diagnostic connector

C--005A

A/C compressor electromagnetic clutch connector

C--010A

Cab roof lights connector

C--035

Windshield wiper motor connector for cabs with openable windows

C--029

Windshield wiper motor connector for cabs with fixed windows

C--029A

Connector for light on number plate light cable

C--020

Battery cut--off fitting connector

C--001C

25A power socket connector (ISO)

C--002A

40A power socket connector (NASO)

C--002B

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DESCRIPTION

CODE

8A power socket connector

C--001A

Engine cable main connector

C--001

Cab roof cable main connector

C--005

Transmission cable main connector

C--003

3rd distributor splitter extension connector

C--006

Rotating beacon socket extension connector (version without cab)

C--056A

Auxiliary socket extension connector (version without cab)

C--002C

Right--hand rotating beacon socket connector

C--024

Left--hand rotating beacon socket connector

C--025

Front headlights extension connector

C--013

Seven--pin extension connector

C--012

Right--hand fan extension connector

C--047

Left--hand fan extension connector

C--046

Instrument panel connector

C--009

Instrument panel connector

C--010

Instrument panel connector

C--011

Pneumatic seat connector

C--001B

Brake lights signal connector

C--041

Seven--pin connector (ISO)

C--003A

Seven--pin connector (NASO)

C--003B

Jumper to be fitted without battery cut--off

C--001D

Jumper for work lights

C--035B

Jumper for road lights

C--035A

Jumper for road lights and work lights

C--035C

AUDIO DEVICES RH speaker

AUT--002

LH speaker

AUT--001

Radio

AUT--003

Horn

AUT--004

SOLENOID VALVES A/C actuator solenoid

SOL--043

3rd distributor splitter actuator solenoid

SOL--001

Four--wheel drive solenoid

SOL--002

Engine stop solenoid

SOL--005

FUSE

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DESCRIPTION

CODE

Grid heater 125A power fuse

F--001GH

Cab user 50A power fuse

F--M005

Deck user 50A power fuse

F--M004

Lights circuit protection fuse NASO -- F--003 (40A)

F--003

5A fuse protecting memory of control panel and safety devices

F--1m

SWITCH A/C switch

SW--028

Parking block switch (NASO)

SW--024A

Home / Enter switch

SW--032

Switch switching headlights onto work lights

SW--023

Full--beam/low--beam headlight switch

SW--003

Starting switch

SW--715

3rd distributor splitter switch

SW--001

4WD Switch

SW--021

Emergency switch (ISO)

SW--002

Emergency switch (NASO)

SW--002A

Handbrake switch

SW--024

Rotating beacon switch

SW--013

KSB switch

SW--008

Brake oil level switch

SW--011

Rear window wiper pump motor switch

SW--015

Rear window wiper motor switch

SW--028A

Windscreen wiper motor switch

SW--017

Brake pedal switch for four--wheel drive

SW--027

Brake pedal switch for brake lights

SW--026

Power take--off switch (mechanical version)

SW--005

Power take--off switch (hydraulic version)

SW--005A

Operator present switch

SW--006

Engine oil pressure switch

SW--007

Swivel lights switch (version without cab)

SW--020A

Work lights switch

SW--020

Switch on the door

SW--019

A/C fan switch

SW--030

LAMPS RH tail lights

LMP--021

Right rear lights (NASO)

LMP--021A

Front RH light

LMP--019

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DESCRIPTION

CODE

Right front light (NASO)

LMP--019A

Front LH light

LMP--018

Left front light (NASO)

LMP--018A

LH tail light

LMP--020

Left rear light (NASO)

LMP--020A

Left rear light on number plate light cable

LMP--020C

Direction indicator on the right mudguard (NASO)

LMP--055

Direction indicator on the left mudguard (NASO)

LMP--054

Direction indicator on cab roof right (NASO)

LMP--049

Direction indicator on cab roof left (NASO)

LMP--048

Cab spot light

LMP--042

Number plate light

LMP--036

Right number plate light on roof

LMP--038

Left number plate light on roof

LMP--037

Front right work lights

LMP--030

Front left work lights

LMP--031

Work lights on right handrail

LMP--050

Work lights on left handrail

LMP--051

Rear work lights (version without a cab)

LMP--030A

Right rear work lights

LMP--032

Left rear work lights

LMP--033

Overhead lighting

LMP--034

RH swivel position light

LMP--015

LH swivel position light

LMP--014

Right--hand light

LMP--017

Left--hand light

LMP--016

Cigar lighter backlighting

LMP--023

Optional cigar lighter backlighting

LMP--040

Home/Enter switch backlighting

LMP--033A

Lights switch backlighting

LMP--029

Four--wheel drive switch backlighting

LMP--022

Rotating beacon switch backlighting

LMP--014A

Windshield wiper motor switch backlighting

LMP--018C

Rear window wiper pump switch backlighting

LMP--016A

Swivel lights switch backlighting (version without cab)

LMP--020B

A/C panel backlighting

LMP--028

GROUNDS Main cable ground

GND--001

Main cable ground

GND--004 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DESCRIPTION

CODE

Platform / transmission ground

GND--002A

25A auxiliary socket extension ground (version without cab)

GND--005

40A auxiliary socket extension ground (version without cab)

GND--006

Cab roof ground

GND--003

Transmission ground

GND--002

MOTORS Starter motor

M--004

Windshield wiper pump motor

M--007

Rear window wiper pump motor

M--008

RELAY Grid heater relay

RLY--001GH

HEATING ELEMENT Cigar lighter heating element

RES--022

Optional cigar lighter heating element

RES--039

Grid heater element

RES--001

Fan resistor

RES--093

SENSOR Steering Pressure Switch

SEN--003

Water in fuel sensor

SEN--006

Gearbox neutral sensor

SEN--002

A/C pressure sensor

SEN--009

Engine rpm sensor

SEN--009A

Air filter clogged sensor

SEN--012

KSB sensor

SEN--004A

Fuel level sensor

SEN--004

A/C temperature sensor

SEN--031

Engine coolant temperature sensor

SEN--008

Anti--frost thermostatic sensor

SEN--044

Tractor speed sensor

SEN--010

BATTERY CUT- OUT Battery cut--out switch

84419869A - 06 - 2011

CB--001

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LIST OF TABLES OF NEW UTILITY SERIES SYSTEM WITHOUT CAB “STANDARD”

Diagram

Market

Description

Page

Diagram 1

ISO NASO

Grid heater, auxiliary socket and cigar lighter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Grid heater, auxiliary sockets, direction indicators and cigar lighter . . . . . . . . . . . . 58

Diagram 2

ISO

Hazard lights and rotating beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Diagram 2

NASO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Diagram 3

ISO_NASO Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Diagram 4

ISO--NASO Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Diagram 5

ISO

Trailer socket, diagnostics and speed sensor battery cut--off fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Diagram 5

NASO

Trailer socket, diagnostics and speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Diagram 6

ISO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Diagram 6

NASO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Diagram 7

ISO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Diagram 7

NASO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Diagram 8

ISO--NASO Control relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Diagram 9

ISO

Starting engine sensors and battery cut--off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Diagram 9

NASO

Starting engine sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Diagram 10 ISO

4WD circuit and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Diagram 10 NASO

Brakes circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

NOTE: On the following page the list of tables and the relevant page number of the circuit “FULL OPTIONAL”.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LIST OF TABLES OF NEW UTILITY SERIES SYSTEM WITHOUT CAB “FULL OPTIONAL”

Diagram

Market

Description

Page

Diagram 1

ISO NASO

Grid heater, auxiliary sockets, work lights, cigar lighter and 3rd distributor splitter, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Grid heater, auxiliary sockets, work lights, cigar lighter and direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

Diagram 2

ISO

Hazard lights and rotating beacon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Diagram 2

NASO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Diagram 3

ISO_NASO Instrument panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Diagram 4

ISO--NASO Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Diagram 5

ISO

Trailer socket, diagnostics, speed sensor and battery cut--off fitting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Diagram 5

NASO

Trailer socket, diagnostics and speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Diagram 6

ISO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Diagram 6

NASO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Diagram 7

ISO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Diagram 7

NASO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Diagram 9

ISO--NASO Control relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Diagram 9

ISO

Starting engine sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Diagram 9

NASO

Starting engine sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Diagram 10 ISO

4WD circuit and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Diagram 10 NASO

4WD circuit and brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

NOTE: On the following page the list of tables and the relevant page number of the circuit “STANDARD”.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

ELECTRIC CIRCUITS COMPONENTS FOR VERSION WITHOUT CAB (With the code in ascending order) PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

ALT--001

Alternator

AUT--004

Horn

BAT--001

Battery

C--001

Engine cable main connector

1--4--5--6--9

1--4--6--9

C--001A

8A power socket connector

C--001C

Battery cut--off fitting connector

C--001D

Jumper to be fitted without battery cut--off

C--001E

Memory cable connector to be fitted when there is a battery cut--out

C--002

Power cable connector

C--002A

25A power socket connector (ISO)

C--002B

40A power socket connector (NASO)

C--002C

Auxiliary socket extension connector (version without cab)

C--003

Transmission cable main connector

3--4--5--10

C--003A

Seven--pin connector (ISO)

C--003B

Seven--pin connector (NASO)

C--005A

Diagnostic connector

C--005B

Power take--off extension cable connector (mechanical version)

C--006

3rd distributor splitter extension connector

C--009

Instrument panel connector

C--010

Instrument panel connector

C--011

Instrument panel connector

C--012

Seven--pin extension connector

C--013

Front headlights extension connector

C--020

Connector for light on number plate light cable

C--024

Right--hand rotating beacon socket connector

C--025

Left--hand rotating beacon socket connector

C--056A

Rotating beacon socket extension connector (version without cab)

CB--001

Battery cut--out switch

F--001GH

Grid Heater 125A mega--fuse

F--M004

Deck service 50A mega fuse

F--1m

5A fuse protecting memory of control panel and safety devices

GND--001

Main cable ground

1--2--3--6--9

GND--002

Transmission ground

5--10

GND--002A

Platform / cab ground

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

CODE

DESCRIPTION

GND--004

Main cable ground

GND--005

PRESENT IN THE TABLES ISO NASO 1--2--5--6--8--10

1--2--5--6--8--10

25A auxiliary socket extension ground (version without cab)

GND--006

40A auxiliary socket extension ground (version without cab)

LMP--014

LH swivel position light

LMP--014A

Rotating beacon switch backlighting

LMP--015

RH swivel position light

LMP--016

Left--hand light

LMP--017

Right--hand light

LMP--018

Front LH light

LMP--018A

Left front light (NASO)

LMP--019

Front RH light

LMP--019A

Right front light (NASO)

LMP--020

LH tail light

LMP--020A

Left rear light (NASO)

LMP--020B

Swivel lights switch backlighting (version without cab)

LMP--020C

Left rear light on number plate light cable

LMP--021

RH tail lights

LMP--021A

Right rear lights (NASO)

LMP--022

Four--wheel drive switch backlighting

LMP--030A

Rear work light (version without a cab)

LMP--033A

Home/Enter switch backlighting

LMP--036

Number plate light

LMP--040

Optional cigar lighter backlighting

LMP--048

Direction indicator on cab roof left (NASO)

LMP--049

Direction indicator on cab roof right (NASO)

LMP--054

Direction indicator on the left mudguard (NASO)

LMP--055

Direction indicator on the right mudguard (NASO)

M--004

Starter motor

MOD--001A

Fuse module*

F--21 (5A)

MOD--001B

Relay module

MOD--001C

Fuse and Relay module*

RLY--4

RLY--7

Power fuse module

MOD--3/4

84419869A - 06 - 2011

6 6

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

MOD--004

Electronic flasher module (ISO)

MOD--004A

Electronic flasher module (NASO)

MOD--1_ADIC Control panel module

MOD--320

Memory fuse module

RES--001

Grid heater element

RES--039

Optional cigar lighter heating element

RLY--001GH

Grid heater relay

SEN--002

Gearbox neutral sensor

SEN--003

Steering Pressure Switch

SEN--004

Fuel level sensor

SEN--004A

KSB sensor

SEN--006

Water in fuel sensor

SEN--008

Engine coolant temperature sensor

SEN--009A

Engine rpm sensor

SEN--010

Tractor speed sensor

SEN--012

Air filter clogged sensor

SOL--001

3rd distributor splitter actuator solenoid

SOL--002

Four--wheel drive solenoid

SOL--005

Engine stop solenoid

SW--001

3rd distributor splitter switch

SW--002

Emergency switch (ISO)

SW--002A

Emergency switch (NASO)

SW--003

Full--beam/low--beam headlight switch

SW--005

Power take--off switch (hydraulic version)

SW--005A

Power take--off switch (mechanical version)

SW--006

Operator present switch

SW--007

Engine oil pressure switch

SW--008

KSB switch

SW--011

Brake oil level switch

SW--013

Rotating beacon switch

SW--020A

Swivel lights switch (version without cab)

SW--021

Four--wheel drive switch

SW--024

Handbrake switch

SW--024A

Parking block switch (NASO)

SW--026

Brake pedal switch for brake lights

SW--027

Brake pedal switch for four--wheel drive

SW--032

Home / Enter switch

SW--715

Starting switch

(*) All the fuses or relays are present except for the ones listed below.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD GRID HEATER, AUXILIARY SOCKET

(Diagram 1 --ISO / NASO)

C--001 Engine cable main connector C--001A 8A power socket connector GND--004 Main cable ground F--001GH Grid heater 125A mega fuse (receives +12V directly from the battery via the alternator) RLY--001GH Grid heater relay RES--001 Grid heater element

* CIGAR LIGHTER

(DIAGRAM 1 -- ISO) GND--001 Main cable ground LMP--040 Optional cigar lighter backlighting RES--039 Optional cigar lighter heating element

* * TOP REAR DIRECTION INDICATORS, AUXILIARY SOCKET AND CIGAR LIGHTER (Diagram 1 -- NASO)

C--002B 40A power socket connector (NASO) C--002C Auxiliary socket extension connector (version without cab) GND--001 Main cable ground GND--006 40A socket extension cable ground (version without cab) LMP--040 Optional cigar lighter backlighting LMP--048 Direction indicator on cab roof left (NASO) LMP--049 Direction indicator on cab roof right (NASO) RES--039 Optional cigar lighter heating element

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 1 -- ISO / NASO

MMR0001A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 FULL OPTIONAL GRID HEATER, AUXILIARY SOCKET AND WORK LIGHT

(Diagram 1 --ISO / NASO)

C--001 Engine cable main connector C--001A 8A power socket connector F--001GH Grid heater 125A mega fuse (receives +12V directly from the battery via the alternator) GND--001 Main cable ground GND--004 Main cable ground LMP--030A Rear work light (version without a cab) RLY--001GH Grid heater relay RES--001 Grid heater element

* 3rd DISTRIBUTOR SPLITTER AND CIGAR LIGHTER (DIAGRAM 1 -- ISO)

C--002A 25A power socket connector (ISO) C--002C Auxiliary socket extension connector (version without cab) C--006 3rd distributor splitter extension connector GND--001 Main cable ground GND--005 25A auxiliary socket extension ground (version without cab) GND--004 Main cable ground LMP--040 Optional cigar lighter backlighting MOD--001A Fuse box and main relay F--21 (+12V pin 15-- 15B from SW--715)-- 3rd distributor splitter circuit MOD--001C Fuse box and main relay RLY--4 3rd distributor splitter control relay RES--039 Optional cigar lighter heating element SOL--001 3rd distributor splitter actuator solenoid SW--001 3rd distributor splitter switch * * TOP REAR DIRECTION INDICATORS AND CIGAR LIGHTER

(Diagram 1 -- NASO)

C--002B 40A power socket connector (NASO) C--002C Auxiliary socket extension connector (version without cab) GND--001 Main cable ground GND--006 40A auxiliary socket extension ground (version without cab) LMP--040 Optional cigar lighter backlighting LMP--048 Direction indicator on cab roof left (NASO) LMP--049 Direction indicator on cab roof right (NASO) RES--039 Optional cigar lighter heating element 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 1 -- ISO / NASO

MMR0002A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL HAZARD LIGHTS AND ROTATING BEACON

(Diagram 2 -- ISO)

C--024 Right--hand rotating beacon socket connector C--025 Left--hand rotating beacon socket connector C--056A Rotating beacon socket extension connector (version without cab) GND--001 Main cable ground GND--004 Main cable ground LMP--014A Main cable ground MOD--004 Electronic flasher module (ISO) SW--002 Emergency switch (ISO) SW--003 Full--beam/low--beam headlight switch SW--013 Rotating beacon switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 2 -- ISO

MMR0003A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL HAZARD LIGHTS

(Diagram 2 -- NASO)

GND--001 Main cable ground GND--004 Main cable ground MOD--004A Electronic flasher module (NASO) SW--002A Emergency switch (NASO) SW--003 Full--beam/low--beam headlight switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 2 -- NASO

MMR0004A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL INSTRUMENT PANEL

(Diagram 3 ISO / NASO)

C--003 Transmission cable main connector C--009 Instrument panel connector C--010 Instrument panel connector C--011 Instrument panel connector GND--001 Main cable ground LMP--033A Home/Enter switch backlighting MOD--1_ADIC Control panel module SEN--004 Fuel level sensor SW--032 CAL switch

* *

On the “NASO Standard” version, there is no wire in the connector C--010 to pin 5. On the “NASO Standard and Full Optional” version, there is no wire in the connectors C--010 to pin 9 and 10 and C--009 to pin 9.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 3 -- ISO / NASO

MMR0005A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL SAFETY CIRCUIT

(Diagram 4 -- ISO / NASO)

C--001 Engine cable main connector C--003 Transmission cable main connector C--005B Power take--off extension cable connector (mechanical version) SEN--002 Gearbox neutral sensor SEN--003 Steering Pressure Switch SW--005 Power take--off switch (hydraulic version)** SW--005A Power take--off switch (mechanical version)* SW--006 Operator present switch *

Extension and switch to use in the power take--off versions for cab models with mechanical clutch engagement. ** Switch for power take--off versions for cab models with hydraulic clutch.

* PARKING BRAKE (Diagram 4 ISO)

SW--024 Handbrake switch (ISO)

* * PARKING BLOCK (Diagram 4 NASO)

C--003 Transmission cable main connector SW--024A Parking block switch (NASO)

(!!) The parking block switch SW--024A, for NASO models, version without cab and the power steering pressure switch sensor SEN--003, for all the versions, again version without cab, use the connector: for SW--024B on the main cable and SEN--003 on the engine cable. (@@) On the transmission cable for the NASO model, version without cab, ignore the connector to the switch SW--024B, using the one on the main cable NASO model. On the transmission cable for the ISO and NASO model, version without cab, ignore the connector to the sensor SEN--0003, using the one on the engine cable. 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 4 -- ISO / NASO

MMR0006A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL TRAILER SOCKET, DIAGNOSTICS, SPEED SENSOR AND BATTERY CUT--OFF FITTING

(Diagram 5 -- ISO)

C--001 Engine cable main connector C--001C Battery cut--off fitting connector C--001D Jumper to be fitted without battery cut--off C--003 Transmission cable main connector C--003A Seven--pin connector (ISO) C--005A Diagnostic connector C--012 Seven--pin extension connector GND--002 Transmission ground GND--004 Main cable ground SEN--010 Tractor speed sensor

When there is a battery cut--off, connect the connector C--001E, see table 10 ISO in place of the connector C--001D.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 5 -- ISO

MMR0007A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL TRAILER SOCKET, DIAGNOSTICS AND SPEED SENSOR

(Diagram 5 -- NASO)

C--003 Transmission cable main connector C--003B Seven--pin connector (NASO) C--005A Diagnostic connector C--012 Seven--pin extension connector GND--002 Transmission ground GND--004 Main cable ground SEN--010 Tractor speed sensor

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 5 -- NASO

MMR0008A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL LIGHTS CIRCUIT

(Diagram 6 -- ISO)

AUT--004 Horn C--001 Engine cable main connector C--013 Front headlights extension connector C--020 Connector for light on number plate light cable GND--001 Main cable ground GND--004 Main cable ground LMP--014 LH swivel position light LMP--015 RH swivel position light LMP--016 Left--hand light LMP--017 Right--hand light LMP--018 Front LH light LMP--019 Front RH light LMP--020 LH tail light LMP--020B Swivel lights switch backlighting (version without cab) LMP--020C Left rear light on number plate light cable LMP--021 RH tail lights LMP--036 Number plate light SW--020A Swivel lights switch (version without cab)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 6 -- ISO

MMR0009A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL LIGHTS CIRCUIT

(Diagram 6 -- NASO)

AUT--004 Horn C--001 Engine cable main connector C--013 Front headlights extension connector GND--001 Main cable ground GND--004 Main cable ground LMP--014 LH swivel position light LMP--015 RH swivel position light LMP--016 Left--hand light LMP--017 Right--hand light LMP--018A Left front light (NASO) LMP--019A Right front light (NASO) LMP--020A Left rear light (NASO) LMP--020B Swivel lights switch backlighting (version without cab) LMP--021A Right rear lights (NASO) SW--020A Swivel lights switch (version without cab)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 6 -- NASO

MMR0010A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD FUSES FOR THE ELECTRICAL SUPPLY

(Diagram 7 -- ISO)

MOD--001A Fusemodul F- 1

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

F- 2

(+12V from F--M004) Hazard lights switch

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Hazard lights switch

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting CAL switch

F- 17

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 20

(+12V from F--M004) Instrument panel power supply

F- 24

(+12V from F--M004) Cigar lighter

F- 26

(+12V from F--M004) Rotating beacon switch

F- 27

(+12V from pin 15--SW--715) Swivel lights switch

SW--715 Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 7 -- ISO

MMR0011A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD FUSES FOR THE ELECTRICAL SUPPLY

(Diagram 7 NASO)

MOD--001A Fusemodul F- 1

(+12V from F--M004) Emergency switch and flasher

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Full--beam/low--beam headlight switch and flasher

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 15

(+12V from F--M004) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Rear left light and backlighting CAL switch

F- 17

(+12V from pin 87--RLY--2) Rear right light and backlighting switches

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 20

(+12V from F--M004) Instrument panel power supply

F- 24

(+12V from F--M004) Cigar lighter

F- 27

(+12V from pin 15--SW--715) Swivel lights switch

F- 31

(+12V from F--M004) 40A auxiliary socket

SW--715 Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 7 -- NASO

MMR0012A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

FULL OPTIONAL FUSES FOR THE ELECTRICAL SUPPLY

(Diagram 7 -- ISO)

MOD--001A Fusemodul F- 1

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

F- 2

(+12V from F--M004) Hazard lights switch

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Hazard lights switch

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting CAL switch

F- 17

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 20

(+12V from F--M004) Instrument panel power supply

F- 24

(+12V from F--M004) Cigar lighter

F- 25

(+12V from pin 15--SW--715) Work light

F- 26

(+12V from F--M004) Rotating beacon switch

F- 27

(+12V from pin 15--SW--715) Swivel lights switch

F- 31

(+12V from F--M004) 25A auxiliary socket

SW--715 Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 7 -- ISO

MMR0013A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

FULL OPTIONAL FUSES FOR THE ELECTRICAL SUPPLY

(Diagram 7 NASO)

MOD--001A Fusemodul F- 1

(+12V from F--M004) Emergency switch and flasher

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Full--beam/low--beam headlight switch and flasher

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 15

(+12V from F--M004) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Rear left light and backlighting CAL switch

F- 17

(+12V from pin 87--RLY--2) Rear right light and backlighting switches

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 20

(+12V from F--M004) Instrument panel power supply

F- 24

(+12V from F--M004) Cigar lighter

F- 25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F- 27

(+12V from pin 15--SW--715) Swivel lights switch

F- 31

(+12V from F--M004) 40A auxiliary socket

SW--715 Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 7 -- NASO

MMR0014A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD -- FULL OPTIONAL CONTROL RELAY

(Diagram 8 -- ISO / NASO)

GND--004 Main cable ground MOD--001B Relay module RLY- MR1 Starting RLY- 27

Starting safety

MOD--001C Fuse and Relay module RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, backlighting switches

RLY- 3

Main beam headlights

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 8 -- ISO / NASO

MMR0015A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD -- FULL OPTIONAL STARTING ENGINE SENSORS START AND BATTERY CUT--OFF

(Diagram 9 -- ISO)

ALT--001 Alternator BAT--001 Battery C--001 Engine cable main connector C--002 Power cable connector CB--001 Battery cut--out switch GND--001 Main cable ground M--004 Starter motor MOD--3/4 Power fuse module F- M004 Deck service 50A mega fuse SEN--004A KSB sensor SEN--006 Water in fuel sensor SEN--008 Engine coolant temperature sensor SEN--009A Engine rpm sensor SEN--012 Air filter clogged sensor SOL--005 Engine stop solenoid SW--007 Engine oil pressure switch SW--008 KSB switch SW--011 Brake oil level switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 9 -- ISO

MMR0016A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD -- FULL OPTIONAL STARTING ENGINE SENSORS

(Diagram 9 -- NASO)

ALT--001 Alternator BAT--001 Battery C--001 Engine cable main connector C--002 Power cable connector GND--001 Main cable ground M--004 Starter motor MOD--3/4 Power fuse module F- M004 Deck service 50A mega fuse SEN--004A KSB sensor SEN--006 Water in fuel sensor SEN--008 Engine coolant temperature sensor SEN--009A Engine rpm sensor SEN--012 Air filter clogged sensor SOL--005 Engine stop solenoid SW--007 Engine oil pressure switch SW--008 KSB switch SW--011 Brake oil level switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 9 -- NASO

MMR0017A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD -- FULL OPTIONAL 4WD CIRCUIT, BRAKES AND MEMORY CABLE

(Diagram 10 -- ISO)

C--001E Memory cable connector to be fitted when there is a battery cut--out C--003 Transmission cable main connector GND--002 Transmission ground GND--002A Platform / transmission ground GND--004 Main cable ground LMP--022 Four--wheel drive switch backlighting MOD--001C Fuse and Relay module RLY- 7

Brake lights

MOD--320 Memory fuse module F- 1m

5A fuse protecting memory of control panel and safety devices

SOL--002 Four--wheel drive solenoid SW--021 Four--wheel drive switch SW--026 Brake pedal switch for brake lights SW--027 Brake pedal switch for four--wheel drive

NOTE: Fitting the switches on the brake pedals (SW- 026 and SW- 027), above all with the electro--hydraulic 4WD version: these must be fitted not in the rest condition (released) but but in their working condition (already pressed). With the switches fitted, without operating the pedals, the pins 1 and 4 instead of being normally open become normally closed the pins 2 and 3 instead of being normally closed become normally open. They are shown on the diagram in the above--mentioned way without operating the pedals. For reasons of safety, any fault found on the switches and on the circuit, the brake lights will switch on(if there is current) and the 4WD will not disengage.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 10 -- ISO

MMR0018A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

STANDARD

*BRAKES CIRCUIT

(Diagram 10 -- NASO)

GND--002 Transmission ground GND--002A Platform / transmission ground GND--004 Main cable ground MOD--001C Fuse and Relay module RLY- 7

Brake lights

SW--026 Brake pedal switch for brake lights

FULL OPTIONAL **4WD CIRCUIT AND BRAKES

(Diagram 10 -- NASO)

C--003 Transmission cable main connector GND--002 Transmission ground GND--002A Platform / transmission ground GND--004 Main cable ground LMP--022 Four--wheel drive switch backlighting MOD--001C Fuse and Relay module RLY- 7

Brake lights

SOL--002 Four--wheel drive solenoid SW--021 Four--wheel drive switch SW--026 Brake pedal switch for brake lights SW--027 Brake pedal switch for four--wheel drive NOTE: Fitting the switches on the brake pedals (SW- 026 and SW- 027), above all with the electro--hydraulic 4WD version, they must be fitted not in the rest condition (released) but but in their working condition (already pressed). With the switches fitted, without operating the pedals, the pins 1 and 4 instead of being normally open become normally closed the pins 2 and 3 instead of being normally closed become normally open. They are shown on the diagram in the above--mentioned way without operating the pedals. For reasons of safety, any fault found on the switches, the brake lights will switch on and the 4WD will not disengage.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DIAGRAM 10 -- ISO / NASO

MMR0019A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

LIST OF TABLES OF NEW UTILITY SERIES SYSTEM WITH CAB “STANDARD” Diagram

Market

Description

Page

Diagram 1

ISO NASO

Grid heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Grid heater and top rear direction indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Diagram 2

ISO--NASO Cigar lighter and auxiliary sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Diagram 3

ISO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Diagram 3

NASO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Diagram 4

ISO--NASO Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Diagram 5

ISO--NASO Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Diagram 6

ISO

Trailer socket, diagnostics, speed sensor and fitting for battery cut--out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Diagram 6

NASO

Trailer socket, diagnostics and speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Diagram 7

ISO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Diagram 7

NASO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Diagram 8

ISO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Diagram 8

NASO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Diagram 9

ISO--NASO Control relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Diagram 10 ISO

Starting engine sensors and battery cut--off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Diagram 10 NASO

Starting and engine sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Diagram 11 ISO--NASO Heating, ventilation and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Diagram 12 ISO

Windscreen wipers and rotating beacon sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Diagram 12 NASO

Windscreen wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Diagram 13 ISO--NASO Power supply fuses and cab control relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Diagram 14 ISO

Work lights, road lights and cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Diagram 14 NASO

Work lights, road lights and cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Diagram 15 ISO NASO

Circuit for brakes and memory power supply and safety systems . . . . . . . . . . . . 158 Brakes circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

NOTE: On the following page the list of tables and the relevant page number of the circuit “FULL OPTIONAL”.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

“FULL OPTIONAL”

Diagram

Market

Description

Page

Diagram 1

ISO NASO

Grid heater and 3rd distributor splitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106 Grid heater and top rear direction indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Diagram 2

ISO--NASO Cigar lighters, auxiliary sockets and radio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Diagram 3

ISO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Diagram 3

NASO

Hazard lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Diagram 4

ISO--NASO Control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Diagram 5

ISO--NASO Safety circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

Diagram 6

ISO

Trailer socket, diagnostics, speed sensor and fitting for battery cut--out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Diagram 6

NASO

Trailer socket, diagnostics and speed sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Diagram 7

ISO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Diagram 7

NASO

Lights circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Diagram 8

ISO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Diagram 8

NASO

Power supply fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Diagram 9

ISO

Control relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Diagram 9

NASO

Control relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Diagram 10 ISO

Starting engine sensors and battery cut--off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Diagram 10 NASO

Starting and engine sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Diagram 11 ISO--NASO Heating, ventilation and air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Diagram 12 ISO

Windscreen wipers and rotating beacon sockets . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Diagram 12 NASO

Windscreen wipers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Diagram 13 ISO--NASO Power supply fuses and cab control relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150 Diagram 14 ISO

Work lights, road lights and cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Diagram 14 NASO

Work lights, road lights and cab lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Diagram 15 ISO NASO

NOTE: On the following page the list of tables and the relevant page number of the circuit “STANDARD”.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

ELECTRIC CIRCUITS COMPONENTS FOR VERSION WITH CAB (With the code in ascending order) PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

ALT--001

Alternator

AUT--001

LH speaker

AUT--002

RH speaker

AUT--003

Radio

AUT--004

Horn

BAT--001

Battery

C--001

Engine cable main connector

1--6--7--10

1--7--10

C--001A

8A power socket connector

C--001B

Pneumatic seat connector

C--001C

Battery cut--off fitting connector

C--001D

Jumper to be fitted without battery cut--off

C--001E

Memory cable connector to be fitted when there is a battery cut--out

C--002

Power cable connector

C--002A

25A power socket connector (ISO)

C--002B

40A power socket connector (NASO)

C--003

Transmission cable main connector

4--5--6--15

C--003A

Seven--pin connector (ISO)

C--003B

Seven--pin connector (NASO)

C--004

Cab power cable connector

11--13

C--005

Cab roof cable main connector

7--8--9--11--12--14

1--7--8--11--12--14

C--005A

Diagnostic connector

C--005B

Power take--off switch extension cable connector (mechanical version)

C--006

3rd distributor splitter extension connector

C--009

Instrument panel connector

C--010

Instrument panel connector

C--010A

A/C compressor electromagnetic clutch connector

C--011

Instrument panel connector

C--012

Seven--pin extension connector

C--013

Front headlights extension connector

C--020

Connector for light on number plate light cable

C--024

Right--hand rotating beacon socket connector

C--025

Left--hand rotating beacon socket connector

C--029

Windshield wiper motor connector for cabs with openable windows

C--029A

Windshield wiper motor connector for cabs with fixed windows

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

100

PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

C--035

Cab roof lights connector

C--035A

Jumper for road lights

C--035B

Jumper for work lights

C--035C

Jumper for road lights and work lights

C--041

Brake lights signal connector

C--046

Left--hand fan extension connector

C--047

Right--hand fan extension connector

C--056

Fan power supply connector

CB--001

Battery cut--out switch

F--001GH

Grid Heater 125A mega--fuse

F--003

40A fuse protecting lights circuit (NASO)

F--M004

Deck service 50A mega fuse

F--M005

Cab service 50A mega fuse

F--1m

5A fuse protecting memory of control panel and safety devices

GND--001

Main cable ground

2--4--7--10--11--12

2--3--4--7--10--11--12

GND--002

Transmission ground

6--15

GND--002A

Platform / transmission ground

GND--003

Cab roof ground

2--6--7--11--12--13--1 4

1--2--7--11--13--14

GND--004

Main cable ground

1--2--3--6--7--9--11--1 5

2--6--7--9--11--15

LMP--014

LH swivel position light

LMP--014A

Rotating beacon switch backlighting

LMP--015

RH swivel position light

LMP--016

Left--hand light

LMP--016A

Rear window wiper pump switch backlighting

LMP--017

Right--hand light

LMP--018

Front LH light

LMP--018A

Left front light (NASO)

LMP--018C

Windshield wiper motor switch backlighting

LMP--019

Front RH light

LMP--019A

Right front light (NASO)

LMP--020

LH tail light

LMP--020A

Left rear light (NASO)

LMP--020C

Left rear light on number plate light cable

LMP--021

RH tail lights

LMP--021A

Right rear lights (NASO)

LMP--022

Four--wheel drive switch backlighting

LMP--023

Cigar lighter backlighting

LMP--028

A/C panel backlighting

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

101

PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

LMP--029

Lights switch backlighting

LMP--030

Front right work lights

LMP--031

Front left work lights

LMP--032

Right rear work lights

LMP--033

Left rear work lights

LMP--033A

Home/Enter switch backlighting

LMP--034

Overhead lighting

LMP--036

Number plate light

LMP--037

Left number plate light on roof

LMP--038

Right number plate light on roof

LMP--040

Optional cigar lighter backlighting

LMP--042

Cab spot light

LMP--048

Direction indicator on cab roof left (NASO)

LMP--049

Direction indicator on cab roof right (NASO)

LMP--050

Work lights on right handrail

LMP--051

Work lights on left handrail

LMP--054

Direction indicator on the left mudguard (NASO)

LMP--055

Direction indicator on the right mudguard (NASO)

M--004

Starter motor

M--007

Windshield wiper pump motor

M--008

Rear window wiper pump motor

MOD--001A

Fuse module*

F--21 (5A)

F--32 (40A) and F--23 (5A)

Relay module*

RLY--26

Fuse and Relay module*

RLY--4

RLY--7

RLY--8

MOD--002

Cab Fuse and Relay module

MOD--003

Fuse module (NASO)

MOD--3/4

Power fuse module

MOD--004

Electronic flasher module (ISO)

MOD--004A

Electronic flasher module (NASO)

MOD--045

A/C control module

MOD--1_ADIC Control panel module

MOD--320

Memory fuse module

RES--001

Grid heater element

MOD--001B MOD--001C

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102

PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

RES--022

Cigar lighter heating element

RES--039

Optional cigar lighter heating element

RES--093

Fan resistor

RLY--001GH

Grid heater relay

SEN--002

Gearbox neutral sensor

SEN--003

Steering Pressure Switch

SEN--004

Fuel level sensor

SEN--004A

KSB sensor

SEN--006

Water in fuel sensor

SEN--008

Engine coolant temperature sensor

SEN--009

A/C pressure sensor

SEN--009A

Engine rpm sensor

SEN--010

Tractor speed sensor

SEN--012

Air filter clogged sensor

SEN--031

A/C temperature sensor

SEN--044

Anti--frost thermostatic sensor

SOL--001

3rd distributor splitter actuator solenoid

SOL--002

Four--wheel drive solenoid

SOL--005

Engine stop solenoid

SOL--043

A/C actuator solenoid

SW--001

3rd distributor splitter switch

SW--002

Emergency switch (ISO)

SW--002A

Emergency switch (NASO)

SW--003

Full--beam/low--beam headlight switch

SW--005

Power take--off switch (hydraulic version)

SW--005A

Power take--off switch (mechanical version)

SW--006

Operator present switch

SW--007

Engine oil pressure switch

SW--008

KSB switch

SW--011

Brake oil level switch

SW--013

Rotating beacon switch

SW--015

Rear window wiper pump motor switch

SW--017

Windscreen wiper motor switch

SW--019

Switch on the door

SW--020

Work lights switch

SW--021

Four--wheel drive switch

SW--023

Switch switching headlights onto work lights

SW--024

Handbrake switch

SW--024A

Parking block switch (NASO)

SW--026

Brake pedal switch for brake lights

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103

PRESENT IN THE TABLES ISO NASO

CODE

DESCRIPTION

SW--027

Brake pedal switch for four--wheel drive

SW--028

A/C switch

SW--028A

Rear window wiper motor switch

SW--030

A/C fan switch

SW--032

Home / Enter switch

SW--715

Starting switch

(*) All the fuses or relays are present except for the ones listed below.

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104

STANDARD GRID HEATER

(Diagram 1 -- ISO / NASO)

C--001 Engine cable main connector F--001GH Grid heater 125A mega fuse (receives +12V directly from the battery via the alternator) RLY--001GH Grid heater relay RES--001 Grid heater element

* * TOP REAR DIRECTION INDICATORS (Diagram 1 -- NASO)

C--005 Cab roof cable main connector GND--003 Cab roof ground LMP--048 Direction indicator on cab roof left (NASO) LMP--049 Direction indicator on cab roof right (NASO)

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105

DIAGRAM 1 -- ISO / NASO

MDQ0196A

84419869A - 06 - 2011

106

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 FULL OPTIONAL GRID HEATER (Diagram 1 -- ISO / NASO)

C--001 Engine cable main connector F--001GH Grid heater 125A mega fuse (receives +12V directly from the battery via the alternator) RLY--001GH Grid heater relay RES--001 Grid heater element

* 3RD DISTRIBUTOR SPLITTER (DIAGRAM 1 -- ISO)

C--006 3rd distributor splitter extension connector GND--004 Main cable ground MOD--001A Fuse box and main relay F--21 (+12V pin 15-- 15B from SW--715)-- 3rd distributor splitter circuit MOD--001C Fuse box and main relay RLY--4 3rd distributor splitter control relay SOL--001 3rd distributor splitter actuator solenoid SW--001 3rd distributor splitter switch

* * TOP REAR DIRECTION INDICATORS (Diagram 1 -- NASO)

C--005 Cab roof cable main connector GND--003 Cab roof ground LMP--048 Direction indicator on cab roof left (NASO) LMP--049 Direction indicator on cab roof right (NASO)

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

107

DIAGRAM 1 -- ISO / NASO

MDQ0197A

84419869A - 06 - 2011

108

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD CIGAR LIGHTER AND AUXILIARY SOCKETS (Diagram 2 ISO / NASO)

C--001A 8A power socket connector C--001B Pneumatic seat connector C--002B 40A power socket connector (NASO) ** GND--004 Main cable ground LMP--023 Cigar lighter backlighting M--007 Windshield wiper pump motor M--008 Rear window wiper pump motor * RES--022 Cigar lighter heating element RES--039 Optional cigar lighter heating element *

The component (M--008) “rear--window wiper pump motor” is not present on the standard version of the ISO systems. ** The 40A socket (C--002B) will only involve the NASO systems, as a result also the call (8--BJ).

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

109

DIAGRAM 2 -- ISO / NASO

MDQ0198A

84419869A - 06 - 2011

110

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 FULL OPTIONAL CIGAR LIGHTER, AUXILIARY SOCKETS AND RADIO (Diagram 2 ISO / NASO)

AUT--001 LH speaker AUT--002 RH speaker AUT--003 Radio C--001A 8A power socket connector C--001B Pneumatic seat connector C--002A* 25A power socket connector (ISO) C--002B** 40A power socket connector (NASO) GND--001 Main cable ground GND--003 Cab roof ground GND--004 Main cable ground LMP--023 Cigar lighter backlighting LMP--040 Optional cigar lighter backlighting M--007 Windshield wiper pump motor M--008 Rear window wiper pump motor RES--022 Cigar lighter heating element RES--039 Optional cigar lighter heating element

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

111

DIAGRAM 2 -- ISO / NASO

MDQ0200A

84419869A - 06 - 2011

112

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL HAZARD LIGHTS (Diagram 3 ISO)

GND--004 Main cable ground MOD--004 Electronic flasher module (ISO) SW--002 Emergency switch (ISO) SW--003 Full--beam/low--beam headlight switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

113

DIAGRAM 3 -- ISO

MDQ0201A

84419869A - 06 - 2011

114

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL HAZARD LIGHTS (Diagram 3 NASO)

GND--001 Main cable ground MOD--004A Electronic flasher module (NASO) SW--002A Emergency switch (NASO) SW--003 Full--beam/low--beam headlight switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

115

DIAGRAM 3 -- NASO

MDQ0202A

84419869A - 06 - 2011

116

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL INSTRUMENT PANEL (Diagram 4 ISO / NASO)

C--003 Transmission cable main connector C--009 Instrument panel connector C--010 Instrument panel connector C--011 Instrument panel connector GND--001 Main cable ground MOD--1_ADIC Control panel module LMP--033A Home/Enter switch backlighting SEN--004 Fuel level sensor SW--032 Home / Enter switch *

The call “6--HB” concerns only the ISO system.

The call “8--TC” concerns only the NASO system.

***

On the ISO standard model there is no CAL button.

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

117

DIAGRAM 4 -- ISO / NASO

***

MDQ0203A

84419869A - 06 - 2011

118

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD - FULL OPTIONAL SAFETY CIRCUIT (Diagram 5 ISO / NASO)

C--003 Transmission cable main connector C--005B Power take--off switch extension cable connector (mechanical version)* SEN--002 Gearbox neutral sensor SEN--003 Steering Pressure Switch SW--005 Power take--off switch (hydraulic version)** SW--005A Power take--off switch (mechanical version)* SW--006 Operator present switch *

Extension and switch to use in the power take--off versions for cab models with mechanical clutch servo--control. ** Switch for power take--off versions for cab models with hydraulic clutch.

* PARKING BRAKE (Diagram 5 ISO)

SW--024 Handbrake switch

* * PARKING BRAKE (Diagram 5 NASO)

C--003 Transmission cable main connector SW--024A Parking block switch (NASO)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

119

DIAGRAM 5 -- ISO / NASO

MDQ0204A

84419869A - 06 - 2011

120

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL TRAILER SOCKET, DIAGNOSTICS, SPEED SENSOR AND BATTERY CUT--OFF FITTING (Diagram 6 ISO)

On tractors without a battery cut--off fit the jumper, with a battery cut--off fit the cable, see diagram 15 page 94, in the hatched box.

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121

DIAGRAM 6 -- ISO

MDQ0205A

84419869A - 06 - 2011

122

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL TRAILER SOCKET, DIAGNOSTICS AND SPEED SENSOR (Diagram 6 NASO)

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

123

DIAGRAM 6 -- NASO

MDQ0206A

84419869A - 06 - 2011

124

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL LIGHTS CIRCUIT (Diagram 7 ISO)

AUT--004 Horn C--001 Engine cable main connector C--005 Cab roof cable main connector C--013 Front headlights extension connector C--020 Connector for light on number plate light cable GND--001 Main cable ground GND--003 Cab roof ground GND--004 Main cable ground LMP--014 LH swivel position light LMP--015 RH swivel position light LMP--016 Left--hand light LMP--017 Right--hand light LMP--018 Front LH light LMP--019 Front RH light LMP--020 LH tail light LMP--020C Left rear light on number plate light cable LMP--021 RH tail lights *

The extension and the welding SP--039 only with the Italian version of the number plate holder light (LMP--036).

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

125

DIAGRAM 7 -- ISO

MDQ0207A

84419869A - 06 - 2011

126

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL LIGHTS CIRCUIT (Diagram 7 NASO)

AUT--004 Horn C--001 Engine cable main connector C--005 Cab roof cable main connector C--013 Front headlights extension connector GND--001 Main cable ground GND--003 Cab roof ground GND--004 Main cable ground LMP--014 LH swivel position light LMP--015 RH swivel position light LMP--016 Left--hand light LMP--017 Right--hand light LMP--018A Left front light (NASO) LMP--019A Right front light (NASO) LMP--020A Left rear light (NASO) LMP--021A Right rear lights (NASO) LMP--054 Direction indicator on the left mudguard (NASO) LMP--055 Direction indicator on the right mudguard (NASO)

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127

DIAGRAM 7 -- NASO

MDQ0208A

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128

STANDARD FUSES FOR THE ELECTRICAL SUPPLY (Diagram 8 ISO) C--005 Cab roof cable main connector MOD--001A Fusemodul F- 1

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

F- 2

(+12V from F--M004) Hazard lights switch

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Hazard lights switch

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 10

(+12V from pin 15--SW--715) Pneumatic seat

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light

F- 17

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches, cab lighting and number plate lights on roof

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F- 20

(+12V from F--M004) Instrument panel power supply

F- 23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F- 24

(+12V from F--M004) Cigar lighter

F- 25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F- 26

(+12V from F--M004) A/C compressor clutch circuit

SW--715 Starting switch

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

129

DIAGRAM 8 -- ISO

MDQ0209A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

130

FULL OPTIONAL FUSES FOR THE ELECTRICAL SUPPLY (Diagram 8 ISO)

C--005 Cab roof cable main connector MOD--001A Fusemodul F- 1

(+12V from F--M004) Lights control switch (full--beam/low--beam headlight switch)

F- 2

(+12V from F--M004) Hazard lights switch

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Hazard lights switch

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 10

(+12V from pin 15--SW--715) Pneumatic seat

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from pin 15--SW--715) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Front right and rear left light, number plate light, backlighting Home / Enter switch

F- 17

(+12V from pin 87--RLY--2) Front left and rear right light, work lights switch, backlighting switches, cab lighting and number plate lights on roof

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F- 20

(+12V from F--M004) Instrument panel power supply

F- 23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F- 24

(+12V from F--M004) Cigar lighter

F- 25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F- 26

(+12V from F--M004) A/C compressor clutch circuit

F- 31

(+12V from F--M004) 25A auxiliary socket

SW--715 Starting switch 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

131

DIAGRAM 8 -- ISO

MDQ0210A

84419869A - 06 - 2011

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132

STANDARD -- FULL OPTIONAL FUSES FOR THE ELECTRICAL SUPPLY (Diagram 8 NASO) C--005 Cab roof cable main connector MOD--001A Fusemodul F- 1

(+12V from F--M004) Emergency switch and flasher

F- 3

(+12V from F--M004) 8A auxiliary socket

F- 4

(+12V from pin 15--SW--715) Full--beam/low--beam headlight switch and flasher

F- 5

(+12V from pin 15--SW--715) Instrument panel key--controlled power supply

F- 6

(+12V from F--M004) Low--beam headlights

F- 7

(+12V from F--M004) High--beam headlights

F- 8

(+12V from pin 505--SW--715) Starting and starting detection line for the instrument panel

F- 9

(+12V from pin 15--SW--715) Circuit for starting at low temperatures and engine stop

F- 10

(+12V from pin 15--SW--715) Pneumatic seat

F- 11

(+12V from pin 15--SW--715) Operator presence circuit, engine speed sensor and power steering pressure sensor

F- 12

(+12V from pin 15--SW--715) Brakes circuit

F- 13

(+12V from pin 15--SW--715) Fuel decanter filter and brake oil float

F- 14

(+12V from F--M004) Parking brake switch

F- 15

(+12V from F--M004) Diagnostic connector and speed sensor

F- 16

(+12V from pin 87--RLY--2) Rear left light and backlighting Home/Enter switch

F- 17

(+12V from pin 87--RLY--2) Rear right light, work lights switch, backlighting switches and cab lighting

F- 18

(+12V from pin 87--RLY--2) Seven pole socket

F- 19

(+12V from pin 15--SW--715) Work lights switch and cab power supply relay

F- 20

(+12V from F--M004) Instrument panel power supply

F- 23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F- 24

(+12V from F--M004) Cigar lighter

F- 25

(+12V from pin 15--SW--715) Circuit for windshield wipers fitted on fixed glass

F- 26

(+12V from F--M004) A/C compressor clutch circuit

F- 31

(+12V from F--M004) 40A auxiliary socket

MOD--003 Fusemodul F- 003

(+12V from F--M004) Full--beam/low--beam headlight switch

SW--715 Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

133

DIAGRAM 8 -- NASO

MDQ0211A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

134

FULL OPTIONAL CONTROL RELAY (Diagram 9 ISO)

C--005 Cab roof cable main connector GND--004 Main cable ground MOD--001B Relay module RLY- MR1 Starting RLY- 27

Starting safety

MOD--001C Fuse and Relay module RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

Main beam headlights

RLY- 5

Switching dipped beam headlights onto work lights

RLY- 6

Switching main beam headlights onto work lights

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

135

DIAGRAM 9 -- ISO

MDQ0212A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

136

CONTROL RELAY FULL OPTIONAL (Diagram 9 NASO) STANDARD (Diagram 9 ISO / NASO)

GND--004 Main cable ground MOD--001B Relay module RLY- MR1 Starting RLY- 27

Starting safety

MOD--001C Fuse and Relay module RLY- 1

Dipped beam headlights

RLY- 2

Parking lights, number plate, switch backlighting, work lights switch and cab lamp

RLY- 3

Main beam headlights

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

137

DIAGRAM 9 -- ISO / NASO

MDQ0213A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

138

STANDARD -- FULL OPTIONAL STARTING ENGINE SENSORS START AND BATTERY CUT--OFF (Diagram 10 ISO)

ALT--001 Alternator BAT--001 Battery C--001 Engine cable main connector C--002 Power cable connector C--010A A/C compressor electromagnetic clutch connector CB--001 Battery cut--out switch GND--001 Main cable ground M--004 Starter motor MOD--3/4 Power fuse module F- M004 Deck service 50A mega fuse F- M005 Cab service 50A mega fuse SEN--004A KSB sensor SEN--006 Water in fuel sensor SEN--008 Engine coolant temperature sensor SEN--009 A/C pressure sensor SEN--009A Engine rpm sensor SEN--012 Air filter clogged sensor SOL--005 Engine stop solenoid SW--007 Engine oil pressure switch SW--008 KSB switch SW--0011 Brake oil level switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

139

DIAGRAM 10 -- ISO

MDQ0214A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

140

STANDARD -- FULL OPTIONAL STARTING ENGINE SENSORS (Diagram 10 NASO)

ALT--001 Alternator BAT--001 Battery C--001 Engine cable main connector C--002 Power cable connector C--010A A/C compressor electromagnetic clutch connector GND--001 Main cable ground M--004 Starter motor MOD--3/4 Power fuse module F- M004 Deck service 50A mega fuse F- M005 Cab service 50A mega fuse SEN--004A KSB sensor SEN--006 Water in fuel sensor SEN--008 Engine coolant temperature sensor SEN--009 A/C pressure sensor SEN--009A Engine rpm sensor SEN--012 Air filter clogged sensor SOL--005 Engine stop solenoid SW--007 Engine oil pressure switch SW--008 KSB switch SW--0011 Brake oil level switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

141

DIAGRAM 10 -- NASO

MDQ0215A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

142

STANDARD -- FULL OPTIONAL HEATING, VENTILATION AND AIR CONDITIONING (Diagram 11 ISO / NASO)

C--004 Cab power cable connector C--005 Cab roof cable main connector C--046 Left--hand fan extension connector C--047 Right--hand fan extension connector C--056 Fan power supply connector GND--001 Main cable ground GND--003 Cab roof ground GND--004 Main cable ground LMP--028 A/C panel backlighting MOD--001A Fusemodul F- 23

(+12V from pin 15--SW--715) A/C actuator and A/C control unit

F- 32

(+12V from F--M004) Cab ventilation circuit

MOD--001B Relay module RLY- 26

Cab ventilation

MOD--001C Fuse and Relay module RLY- 8

A/C compressor clutch

MOD--045 A/C control module RES--093 Fan resistor SEN--031 A/C temperature sensor SEN--044 Anti--frost thermostatic sensor SOL--43 A/C actuator solenoid SW--028 A/C switch SW--030 A/C fan switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

143

DIAGRAM 11 -- ISO / NASO

MDQ0216A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

144

STANDARD WINDSHIELD WIPERS, AND ROTATING BEACON SOCKETS (Diagram 12 ISO)

C--005 Cab roof cable main connector C--024 Right--hand rotating beacon socket connector C--025 Left--hand rotating beacon socket connector C--029A Windshield wiper motor connector for cabs with fixed windows GND--001 Main cable ground GND--003 Cab roof ground LMP--014A Rotating beacon switch backlighting LMP--016A Rear window wiper pump switch backlighting LMP--018C Windshield wiper motor switch backlighting SW--013 Rotating beacon switch SW--015 Rear window wiper pump motor switch SW--017 Windscreen wiper motor switch SW--028A Rear window wiper motor switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

145

DIAGRAM 12 -- ISO

MDQ0217A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

146

FULL OPTIONAL WINDSHIELD WIPERS, AND ROTATING BEACON SOCKETS (Diagram 12 ISO)

C--005 Cab roof cable main connector C--024 Right--hand rotating beacon socket connector C--025 Left--hand rotating beacon socket connector C--029 Windshield wiper motor connector for cabs with openable windows C--029A Windshield wiper motor connector for cabs with fixed windows GND--001 Main cable ground GND--003 Cab roof ground LMP--014A Rotating beacon switch backlighting LMP--016A Rear window wiper pump switch backlighting LMP--018C Windshield wiper motor switch backlighting SW--013 Rotating beacon switch SW--015 Rear window wiper pump motor switch SW--017 Windscreen wiper motor switch SW--028A Rear window wiper motor switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

147

DIAGRAM 12 -- ISO

MDQ0218A

84419869A - 06 - 2011

148

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL WIPERS (Diagram 12 NASO)

C--005 Cab roof cable main connector C--029A Windshield wiper motor connector for cabs with fixed windows GND--001 Main cable ground LMP--016A Rear window wiper pump switch backlighting LMP--018C Windshield wiper motor switch backlighting SW--015 Rear window wiper pump motor switch SW--017 Windscreen wiper motor switch SW--028A Rear window wiper motor switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

149

DIAGRAM 12 -- NASO

MDQ0219A

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

150

STANDARD -- FULL OPTIONAL POWER SUPPLY FUSES AND CAB CONTROL RELAYS (Diagram 13 ISO / NASO)

C--004 Cab power cable connector GND--003 Cab roof ground MOD--002 Cab Fuse and Relay module

F- 1c

(+12V from F--M005) Front work lights

F- 2c

(+12V from F--M005) Rear work lights

F- 3c

(+12V from F--M005) Switch for rotating beacon and overhead light

F- 5c

(+12V from pin 87 RLY--2c) Fan switch and A/C switch

F- 6c

(+12V from pin 87 RLY--2c) Rear--window wiper and windshield wiper switch, radio, windshield wiper (for openable window) and rear--window wiper pump

RLY- 1c

Rear work lights

RLY- 2c

Power

RLY- 4c

Front work lights

The call “14--FH” concerns only the NASO system.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

151

DIAGRAM 13 -- ISO / NASO

MDQ0220A

84419869A - 06 - 2011

152

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD WORK LIGHTS, ROAD LIGHTS AND CAB LIGHTING (Diagram 14 ISO)

C--005 Cab roof cable main connector C--035 Cab roof lights connector C--035B Jumper for work lights GND--003 Cab roof ground LMP--030 Front right work lights LMP--031 Front left work lights LMP--032 Right rear work lights LMP--033 Left rear work lights LMP--034 Overhead lighting LMP--042 Cab spot light SW--019 Switch on the door SW--020 Work lights switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

153

DIAGRAM 14 -- ISO

MDQ0221A

84419869A - 06 - 2011

154

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 FULL OPTIONAL WORK LIGHTS, ROAD LIGHTS AND CAB LIGHTING (Diagram 14 ISO)

C--005 Cab roof cable main connector C--035 Cab roof lights connector C--035A Jumper for road lights C--035B Jumper for work lights C--035C Jumper for road lights and work lights GND--003 Cab roof ground LMP--029 Lights switch backlighting LMP--030 Front right work lights LMP--031 Front left work lights LMP--032 Right rear work lights LMP--033 Left rear work lights LMP--034 Overhead lighting LMP--042 Cab spot light LMP--050 Work lights on right handrail LMP--051 Work lights on left handrail SW--019 Switch on the door SW--020 Work lights switch SW--023 Switch switching headlights onto work lights

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

155

DIAGRAM 14 ISO

MDQ0222A

84419869A - 06 - 2011

156

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 STANDARD -- FULL OPTIONAL WORK LIGHTS, ROAD LIGHTS AND CAB LIGHTING (Diagram 14 NASO)

C--005 Cab roof cable main connector GND--003 Cab roof ground LMP--030 Front right work lights LMP--031 Front left work lights LMP--032 Right rear work lights LMP--033 Left rear work lights LMP--034 Overhead lighting LMP--042 Cab spot light SW--019 Switch on the door SW--020 Work lights switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

157

DIAGRAM 14 -- NASO

MDQ0223A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

158

STANDARD -- FULL OPTIONAL BRAKES CIRCUIT (Diagram 15 ISO / NASO)

C--003 Transmission cable main connector C--041 Brake lights signal connector GND--002 Transmission ground GND--002A Platform / cab ground GND--004 Main cable ground LMP--022 Four--wheel drive switch backlighting MOD--001C Fuse and Relay module RLY- 7

Brake lights

SOL--002 Four--wheel drive solenoid SW--021 Four--wheel drive switch SW--026 Brake pedal switch for brake lights SW--027 Brake pedal switch for four--wheel drive

* POWER SUPPLY OF MEMORY AND SAFETY SYSTEMS (Diagram 15 ISO)

C--001E Memory cable connector to be fitted when there is a battery cut--out MOD--320 Memory fuse module F- 1m

5A fuse protecting memory of control panel and safety devices

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

159

DIAGRAM 15 ISO / NASO

MDQ0224A

84419869A - 06 - 2011

160

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SECTION 55 -- ELECTRICAL SYSTEM Chapter 6 -- WIRING HARNESSES AND CONNECTORS CONTENTS Description

Page

Electrical circuit components (descriptive order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical circuit components (with code in progressive order) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ELECTRICAL CIRCUIT COMPONENTS (gathered in groups with descriptive order)

DESCRIPTION

CODE

ALTERNATOR Alternator

ALT-001

BATTERY Battery

BAT--001

ELECTRONIC MODULES CONTROL UNITS A/C control module

MOD--045

Memory fuse module

MOD--320

Fusemodul

MOD--001A

Fuse module (NASO)

MOD--003

Fuse and Relay module

MOD--001C

Cab Fuse and Relay module

MOD--002

Power fuse module

MOD--3/4

Electronic flasher module (ISO)

MOD--004

Electronic flasher module (NASO)

MOD--004A

Control panel module

MOD--1_ADIC

Relay module

MOD--001B

CONNECTIONS Parking block connector (NASO without cab)

C--024B

Power cable connector

C--002

Cab power cable connector

C--004

Memory cable connector to be fitted when there is a battery cut--out

C--001E

Power take--off switch extension cable connector (mechanical version)

C--005B

Diagnostic connector

C--005A

A/C compressor electromagnetic clutch connector

C--010A

Cab roof lights connector

C--035

Windshield wiper motor connector for cabs with openable windows

C--029

Windshield wiper motor connector for cabs with fixed windows

C--029A

Connector for light on number plate light cable

C--020

Battery cut--off fitting connector

C--001C

25A power socket connector (ISO)

C--002A

40A power socket connector (NASO)

C--002B

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DESCRIPTION

CODE

8A power socket connector

C--001A

Engine cable main connector

C--001

Fan power supply connector

C--056

Cab roof cable main connector

C--005

Transmission cable main connector

C--003

3rd distributor splitter extension connector

C--006

Rotating beacon socket extension connector (version without cab)

C--056A

Auxiliary socket extension connector (version without cab)

C--002C

Right--hand rotating beacon socket connector

C--024

Left--hand rotating beacon socket connector

C--025

Front headlights extension connector

C--013

Seven--pin extension connector

C--012

Right--hand fan extension connector

C--047

Left--hand fan extension connector

C--046

Instrument panel connector

C--009

Instrument panel connector

C--010

Instrument panel connector

C--011

Pneumatic seat connector

C--001B

Brake lights signal connector

C--041

Seven--pin connector (ISO)

C--003A

Seven--pin connector (NASO)

C--003B

Jumper to be fitted without battery cut--off

C--001D

Jumper for work lights

C--035B

Jumper for road lights

C--035A

Jumper for road lights and work lights

C--035C

AUDIO DEVICES RH speaker

AUT--002

LH speaker

AUT--001

Radio

AUT--003

Horn

AUT--004

SOLENOID VALVES A/C actuator solenoid

SOL--043

3rd distributor splitter actuator solenoid

SOL--001

Four--wheel drive solenoid

SOL--002

Engine stop solenoid

SOL--005

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DESCRIPTION

CODE

FUSE Grid heater 125A power fuse

F--001GH

Cab user 50A power fuse

F--M005

Deck user 50A power fuse

F--M004

Lights circuit protection fuse NASO -- F--003 (40A)

F--003

5A fuse protecting memory of control panel and safety devices

F--1m

SWITCH A/C switch

SW--028

Parking block switch (NASO)

SW--024A

Home / Enter switch

SW--032

Switch switching headlights onto work lights

SW--023

Full--beam/low--beam headlight switch

SW--003

Starting switch

SW--715

3rd distributor splitter switch

SW--001

Four--wheel drive switch

SW--021

Emergency switch (ISO)

SW--002

Emergency switch (NASO)

SW--002A

Handbrake switch

SW--024

Rotating beacon switch

SW--013

KSB switch

SW--008

Brake oil level switch

SW--011

Brake pedal switch for four--wheel drive

SW--027

Brake pedal switch for brake lights

SW--026

Rear window wiper pump motor switch

SW--015

Rear window wiper motor switch

SW--028A

Windscreen wiper motor switch

SW--017

Power take--off switch (mechanical version)

SW--005A

Power take--off switch (hydraulic version)

SW--005

Operator present switch

SW--006

Engine oil pressure switch

SW--007

Swivel lights switch (version without cab)

SW--020A

Work lights switch

SW--020

Switch on the door

SW--019

A/C fan switch

SW--030

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DESCRIPTION

CODE

LAMPS RH tail lights

LMP--021

Right rear lights (NASO)

LMP--021A

Front RH light

LMP--019

Right front light (NASO)

LMP--019A

Front LH light

LMP--018

Left front light (NASO)

LMP--018A

LH tail light

LMP--020

Left rear light (NASO)

LMP--020A

Left rear light on number plate light cable

LMP--020C

Direction indicator on the right mudguard (NASO)

LMP--055

Direction indicator on the left mudguard (NASO)

LMP--054

Direction indicator on cab roof right (NASO)

LMP--049

Direction indicator on cab roof left (NASO)

LMP--048

Rotating lamp on the extension (version without cab)

LMP--056

Cab spot light

LMP--042

Number plate light

LMP--036

Right number plate light on roof

LMP--038

Left number plate light on roof

LMP--037

Front right work lights

LMP--030

Front left work lights

LMP--031

Work lights on right handrail

LMP--050

Work lights on left handrail

LMP--051

Rear work lights (version without a cab)

LMP--030A

Right rear work lights

LMP--032

Left rear work lights

LMP--033

Overhead lighting

LMP--034

RH swivel position light

LMP--015

LH swivel position light

LMP--014

Right--hand light

LMP--017

Left--hand light

LMP--016

Cigar lighter backlighting

LMP--023

Optional cigar lighter backlighting

LMP--040

Home/Enter switch backlighting

LMP--033A

Lights switch backlighting

LMP--029

Four--wheel drive switch backlighting

LMP--022

Rotating beacon switch backlighting

LMP--014A

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DESCRIPTION

CODE

Windshield wiper motor switch backlighting

LMP--018C

Rear window wiper pump switch backlighting

LMP--016A

Swivel lights switch backlighting (version without cab)

LMP--020B

A/C panel backlighting

LMP--028

GROUNDS Main cable ground

GND--001

Main cable ground

GND--004

Platform / cab ground

GND--002A

25A auxiliary socket extension ground (version without cab) 40A auxiliary socket extension ground (version without cab)

GND--005 GND--006

Cab roof ground

GND--003

Transmission ground

GND--002

MOTORS Starter motor

M--004

Windshield wiper pump motor

M--007

Rear window wiper pump motor

M--008

RELAYS Grid heater relay

RLY--001GH

HEATING ELEMENT Cigar lighter heating element

RES--022

Optional cigar lighter heating element

RES--039

Grid heater element

RES--001

Fan resistor

RES--093

SENSOR Steering Pressure Switch

SEN--003

Water in fuel sensor

SEN--006

Gearbox neutral sensor

SEN--002

A/C pressure sensor

SEN--009

Engine rpm sensor

SEN--009A

Air filter clogged sensor

SEN--012

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DESCRIPTION

CODE

KSB sensor

SEN--004A

Fuel level sensor

SEN--004

A/C temperature sensor

SEN--031

Engine coolant temperature sensor

SEN--008

Anti--frost thermostatic sensor

SEN--044

PTO speed sensor

SEN--005

Tractor speed sensor

SEN--010

BATTERY CUT- OUT Battery cut--out switch

CB--001

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SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

ELECTRICAL CIRCUITS COMPONENTS VERSION 1 (With the code in progressive order) CODE

DESCRIPTION

ALT--001

Alternator

AUT--001

LH speaker

AUT--002

RH speaker

AUT--003

Radio

AUT--004

Horn

BAT--001

Battery

C--001

Engine cable main connector

C--001A

8A power socket connector

C--001B

Pneumatic seat connector

C--001C

Battery cut--off fitting connector

C--001D

Jumper to be fitted without battery cut--off

C--001E

Memory cable connector to be fitted when there is a battery cut--out

C--002

Power cable connector

C--002A

25A power socket connector (ISO)

C--002B

40A power socket connector (NASO)

C--002C

Auxiliary socket extension connector (version without cab)

C--003

Transmission cable main connector

C--003A

Seven--pin connector (ISO)

C--003B

Seven--pin connector (NASO)

C--004

Cab power cable connector

C--005

Cab roof cable main connector

C--005A

Diagnostic connector

C--005B

Power take off switch extension cable connector (mechanical version)

C--006

3rd distributor splitter extension connector

C--009

Instrument panel connector

C--010

Instrument panel connector

C--010A

A/C compressor electromagnetic clutch connector

C--011

Instrument panel connector

C--012

Seven--pin extension connector

C--013

Front headlights extension connector

C--020

Connector for light on number plate light cable

C--024

Right--hand rotating beacon socket connector

C--025

Left--hand rotating beacon socket connector

C--029

Windshield wiper motor connector for cabs with openable windows

C--029A

Windshield wiper motor connector for cabs with fixed windows

C--035

Cab roof lights connector

C--035A

Jumper for road lights

C--035B

Jumper for work lights

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CODE

DESCRIPTION

C--035C

Jumper for road lights and work lights

C--041

Brake lights signal connector

C--046

Left--hand fan extension connector

C--047

Right--hand fan extension connector

C--056

Fan power supply connector

C--056A

Rotating beacon socket extension connector (version without cab)

CB--001

Battery cut--out switch

F--001GH

Grid Heater 125A mega--fuse

F--003

40A fuse protecting lights circuit (NASO)

F--M004

Deck service 50A mega fuse

F--M005

Cab service 50A mega fuse

F--1m

5A fuse protecting memory of control panel and safety devices

GND--001

Main cable ground

GND--002

Transmission ground

GND--002A

Platform / cab ground

GND--003

Cab roof ground

GND--004

Main cable ground

GND--005

25A auxiliary socket extension ground (version without cab)

GND--006

40A auxiliary socket extension ground (version without cab)

LMP--014

LH swivel position light

LMP--014A

Rotating beacon switch backlighting

LMP--015

RH swivel position light

LMP--016

Left--hand light

LMP--016A

Rear window wiper pump switch backlighting

LMP--017

Right--hand light

LMP--018

Front LH light

LMP--018A

Left front light (NASO)

LMP--018C

Windshield wiper motor switch backlighting

LMP--019

Front RH light

LMP--019A

Right front light (NASO)

LMP--020

LH tail light

LMP--020A

Left rear light (NASO)

LMP--020B

Swivel lights switch backlighting (version without cab)

LMP--020C

Left rear light on number plate light cable

LMP--021

RH tail lights

LMP--021A

Right rear lights (NASO)

LMP--022

Four--wheel drive switch backlighting

LMP--023

Cigar lighter backlighting

LMP--028

A/C panel backlighting

LMP--029

Lights switch backlighting

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CODE

DESCRIPTION

LMP--030

Front right work lights

LMP--030A

Rear work lights (version without a cab)

LMP--031

Front left work lights

LMP--032

Right rear work lights

LMP--033

Left rear work lights

LMP--033A

Home/Enter switch backlighting

LMP--034

Overhead lighting

LMP--036

Number plate light

LMP--037

Left number plate light on roof

LMP--038

Right number plate light on roof

LMP--040

Optional cigar lighter backlighting

LMP--042

Cab spot light

LMP--048

Direction indicator on cab roof left (NASO)

LMP--049

Direction indicator on cab roof right (NASO)

LMP--050

Work lights on right handrail

LMP--051

Work lights on left handrail

LMP--054

Direction indicator on the left mudguard (NASO)

LMP--055

Direction indicator on the right mudguard (NASO)

LMP--056

Rotating lamp on the extension (version without cab)

M--004

Starter motor

M--007

Windshield wiper pump motor

M--008

Rear window wiper pump motor

MOD--001A

Fusemodul

MOD--001B

Relay module

MOD--001C

Fuse and Relay module

MOD--002

Cab Fuse and Relay module

MOD--003

Fuse module (NASO)

MOD--3/4

Power fuse module

MOD--004

Electronic flasher module (ISO)

MOD--004A

Electronic flasher module (NASO)

MOD--045

A/C control module

MOD--1_ADIC Control panel module MOD--320

Memory fuse module

RES--001

Grid heater element

RES--022

Cigar lighter heating element

RES--039

Optional cigar lighter heating element

RES--093

Fan resistor

RLY--001GH

Grid heater relay

SEN--002

Gearbox neutral sensor

SEN--003

Steering Pressure Switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CODE

DESCRIPTION

SEN--004

Fuel level sensor

SEN--004A

KSB sensor

SEN--005

PTO speed sensor

SEN--006

Water in fuel sensor

SEN--008

Engine coolant temperature sensor

SEN--009

A/C pressure sensor

SEN--009A

Engine rpm sensor

SEN--010

Tractor speed sensor

SEN--012

Air filter clogged sensor

SEN--031

A/C temperature sensor

SEN--044

Anti--frost thermostatic sensor

SOL--001

3rd distributor splitter actuator solenoid

SOL--002

Four--wheel drive solenoid

SOL--005

Engine stop solenoid

SOL--043

A/C actuator solenoid

SW--001

3rd distributor splitter switch

SW--002

Emergency switch (ISO)

SW--002A

Emergency switch (NASO)

SW--003

Full--beam/low--beam headlight switch

SW--005

Power take--off switch (hydraulic version)

SW--005A

Power take--off switch (mechanical version)

SW--006

Operator present switch

SW--007

Engine oil pressure switch

SW--008

KSB switch

SW--011

Brake oil level switch

SW--013

Rotating beacon switch

SW--015

Rear window wiper pump motor switch

SW--017

Windscreen wiper motor switch

SW--019

Switch on the door

SW--020

Work lights switch

SW--020A

Swivel lights switch (version without cab)

SW--021

Four--wheel drive switch

SW--023

Switch switching headlights onto work lights

SW--024

Handbrake switch

SW--024A

Parking block switch (NASO)

SW--026

Brake pedal switch for brake lights

SW--027

Brake pedal switch for four--wheel drive

SW--028

A/C switch

SW--028A

Rear window wiper motor switch

SW--030

A/C fan switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CODE

DESCRIPTION

SW--032

Home / Enter switch

SW--715

Starting switch

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

HARNESSES

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

VERSION LIST OF TABLES OF NEW UTILITY SERIES SYSTEM WITH CAB “FULL OPTIONAL” Diagram

Market

Description

Diagram 1

ISO

Grid heater and 3rd distributor splitter

Diagram 2

ISO

Cigar lighters, auxiliary sockets and radio

Diagram 3

ISO

Hazard lights

Diagram 4

ISO

Control panel

Diagram 5

ISO

Safety circuit

Diagram 6

ISO

Trailer socket, diagnostics, speed sensor and fitting for battery cut--off

Diagram 7

ISO

Lights circuit

Diagram 8

ISO

Power supply fuses

Diagram 9

ISO

Control relay

Diagram 10 ISO

Starting engine sensors and battery cut--off

Diagram 11 ISO

Heating, ventilation and air conditioning

Diagram 12 ISO

Windscreen wipers and rotating beacon sockets

Diagram 13 ISO

Power supply fuses and cab control relays

Diagram 14 ISO

Work lights, road lights and cab lighting

Diagram 15 ISO

Circuit for brakes and memory power supply and safety systems

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CAB MAIN AND CAB ROOF HARNESS Left rear view

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 CAB MAIN AND CAB ROOF HARNESS Right rear view

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

HARNESS FOR ENGINE, POWER SUPPLY AND BATTERY CUT--OFF Right Hand View

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

HARNESS FOR ENGINE, POWER SUPPLY AND BATTERY CUT--OFF Left Hand Side View

4 NOTE: The in a square frame represent the sections of the wiring harness between the tables: table 1 and table 2 for the main wiring harness and cab roof and table 3 and table 4m for the engine wiring harness, power supply and battery cut- off.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

TRANSMISSION WIRING HARNESS

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

CONNECTORS

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Pin Col. Sect. Pin ALT--001 ⇒ MOD--1_ADIC 1st RV 0.75 M--004 ⇒ ALT--001 1b

Col.

Sect.

ALT-- 001

M--004 ⇒ RLY--001GH 1c

a 1

Col.

Sect.

Col.

Sect.

1.0

AUT-- 001

2 Pin 1

Col. AN

Sect. 1.0

Pin 1

Col. A

Sect. 1.0

AUT-- 002

3 Pin 1 2 3 4 5

Col. -G -GN A

Sect. -1.0 -1.0 1.0

Pin 6 7 8 9 --

Col. AN VG -N --

Sect. 1.0 0.5 -1.0 --

AUT-- 003

1 4 7

2 5 8

3 6 9

4 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

AUT-- 004

5 Pin A1 A2 A3 A4 A5

Col. RN SV VN N BZ

Sect. 2.50 0.75 0.75 1.5 0.75

Pin B5 B6 B7 B8 C1

Col. MN H B LV Z

Sect. 0.75 1.5 1.5 0.75 1.0

A6 A7 A8 B1

R N AR V

0.75 1.5 0.75 1.5

C2 C3 C4 C5

SG HN HV HL

1.0 0.75 0.75 1.0

B2 B3

CB RV

0.75 0.75

C6 C7

BR LV

0.75 0.75

1.0

For model without cab ISO (main cable side).

C-- 001

C8 C7 C6 C5 C4 C3 C2 C1 B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

24 Pin A1

Col. RN

Sect. 2.50

Pin B5

Col. MN

Sect. 0.75

A2 A3

SV VN

0.75 0.75

B6 B7

H B

1.5 1.5

A4 A5 A6

N BZ R

1.5 0.75 0.75

B8 C1 C2

LV Z SG

0.75 1.0 1.0

A7 A8

N AR

1.5 0.75

C3 C4

HN HV

0.75 0.75

B1 B2 B3 B4

V B RV LR

1.5 0.75 0.75 1.0

C5 C6 C7 C8

L BR LV CB

1.0 0.75 0.75 0.75

For model with cab ISO (main cable side).

C-- 001

C8 C7 C6 C5 C4 C3 C2 C1 B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

Pin A1 A2 A3 A4 A5

Col. RN MH VN N ZC

Sect. 2.50 0.75 0.75 1.0 0.75

Pin B5 B6 B7 B8 C1

Col. MN H B LV Z

Sect. 0.75 1.5 1.5 0.75 1.0

A6 A7 A8 B1

R N AR V

0.75 1.5 0.75 1.5

C2 C3 C4 C5

SG HN HV L

1.0 0.75 0.75 1.0

B2 B3

B RV

0.75 0.75

C6 C7

BR LV

0.75 0.75

1.0

0.75

Engine cable side.

C-- 001

A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4 B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin A1

Col. RN

Sect. 4.50

Pin B5

Col. MN

Sect. 0.75

A2 A3

SV VN

0.75 0.75

B6 B7

H B

1.5 1.5

A4 A5 A6

N BZ --

1.5 0.75 --

B8 C1 C2

-Z SG

-1.0 1.0

A7 A8

N AR

1.5 0.75

C3 C4

HN HV

0.75 0.75

B1 B2 B3 B4

V CB RV LR

1.5 0.75 0.75 1.0

C5 C6 C7 C8

HL BR ---

0.75 0.75 ---

For model without cab NASO (main cable side).

C-- 001

C8 C7 C6 C5 C4 C3 C2 C1 B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

9 Pin A1 A2 A3 A4 A5 A6 A7 A8 B1 B2 B3 B4

Col. RN SV VN N BZ N N AR V B RV LR

Sect. 2.50 0.75 0.75 1.5 0.75 1.5 1.5 0.75 1.5 0.75 0.75 1.0

Pin B5 B6 B7 B8 C1 C2 C3 C4 C5 C6 C7 C8

Col. MN H B -Z SG HN HV L BR -CB

Sect. 0.75 1.5 1.5 -1.0 1.0 0.75 0.75 1.0 0.75 -0.75

For model with cab NASO (main cable side).

C-- 001

C8 C7 C6 C5 C4 C3 C2 C1 B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

26 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. AB

Sect. 1.5

C-- 001A

11 Pin

Col.

Sect.

Col.

Sect.

1.0

1.5

C-- 001B

1 2 12 Pin 1 3

Col. LV LV

Sect. 0.75 0.75

Pin 2 --

Col. R --

Sect. 0.75 --

C-- 001C

Main cable side.

13 Pin 1 3

Col. -R

Sect. -1.5

Pin 2 --

Col. R --

Sect. 1.5 --

C-- 001C

For ISO model (memory fuse side).

1 2

14 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. LV

Sect. 1.0

Pin 2

Col. LV

Sect. 1.5

C-- 001D

Jumper for tractors without a battery cut--off.

1 2

15 Pin

Col.

Sect.

Col.

Sect.

10.0

C-- 002

For model without cab (main cable side).

16 Pin A

Col. R

Sect. 10.0

Pin B

Col. L

Sect. 10.0

C-- 002

For model with cab (main cable side).

17 Pin A

Col. R

Sect. 10.0

Pin B

Col. L

Sect. 10.0

C-- 002

For model without cab (power cable side).

18 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

28 Pin

Col.

Sect.

Col.

Sect.

10.0

C-- 002

For model with cab (power cable side).

A 19

Pin 1

Col. M

Sect. 4.0

Pin --

Col. --

Sect. --

C-- 002C

For model without cab ISO main cable side.

20 Pin 1

Col. M

Sect. 4.0

Pin --

Col. --

Sect. --

C-- 002C

For model without cab ISO extension side.

21 Pin 1

Col. M

Sect. 4.0

Pin 1

Col. N

Sect. 4.0

C-- 002A

For model without cab ISO.

22 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

6.0

C-- 002C

For model without cab NASO main cable side.

23 Pin 1

Col. M

Sect. 6.0

Pin --

Col. --

Sect. --

C-- 002C

For model without cab NASO extension side.

24 Pin 1

Col. M

Sect. 6.0

Pin 1

Col. N

Sect. 6.0

C-- 002A

For model with cab

25 Pin 1

Col. M

Sect. 6.0

Pin --

Col. --

Sect. --

C-- 002B

For model without cab.

26 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

30 Pin 1

Col. M

Sect. 6.0

Pin 1

Col. N

Sect. 6.0

C-- 002B

For model with cab

27 Pin

Col.

Sect.

Col.

Sect.

1 2 3 4 5 6

-S CN BZ LG VR

-0.75 1.0 0.75 1.0 0.75

8 9 10 11 12 13

LN HG -----

0.75 0.75 -----

0.5

C-- 003

For model without cab ISO and NASO full optional (main cable side).

1 5

9 10 11 12 13 14

28 Pin 1

Col. --

Sect. --

Pin 8

Col. LH

Sect. 0.75

2 3

S --

0.75 --

9 10

HG --

0.75 --

4 5 6 7

BZ LG VR H

0.75 1.0 0.75 0.5

11 12 13 14

-----

C-- 003

For model without cab NASO, standard (main cable side).

9 10 11 12 13 14

29 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. --

Sect. --

Pin 8

Col. LN

Sect. 0.75

2 3

S CN

0.75 1.0

9 10

HG CB

0.75 0.75

4 5 6

BZ LG VR

0.75 1.0 0.75

11 12 13

----

0.5

C-- 003

For model ISO with cab (main cable side).

9 10 11 12 13 14

Pin 1 2 3 4 5 6 7

Col. -S CN BZ LG VR H

Sect. -0.75 1.0 0.75 1.0 0.75 0.5

Pin 8 9 10 11 12 13 14

Col. HL HG CB BL B ---

Sect. 0.75 0.75 0.75 0.75 0.75 ---

C-- 003

For model NASO with cab (main cable side). 3

9 10 11 12 13

2 6

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

32 Pin 1

Col. --

Sect. --

Pin 8

Col. HV

Sect. 0.75

2 3

S CN

1.0 1.0

9 10

HG MH

0.75 0.75

4 5 6

ZB LG VA

1.0 1.0 1.0

11 12 13

----

0.75

C-- 003

For ISO model (transmission side).

2 1 7 6 5 4 3 12 11 10 9 8 14 13

Pin 1 2 3 4 5 6 7

Col. -S CN ZB LG VA H

Sect. -1.0 1.0 1.0 1.0 1.0 0.75

Pin 8 9 10 11 12 13 14

Col. HV HG MH LH B ---

Sect. 0.75 0.75 0.75 0.75 0.75 ---

C-- 003

For NASO model (transmission side).

2 1 7 6 5 4 3 12 11 10 9 8 14 13

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. G

Sect. 1.0

Pin 5

Col. M

Sect. 1.0

2 3

-B

-1.5

6 7

R N

1.0 1.5

1.0

C-- 003A

2 3

For ISO model.

6 5

34 Pin

Col.

Sect.

Col.

Sect.

1 2 3 4

B N G R

1.5 1.5 1.0 1.0

5 6 7 --

V M ---

1.0 1.5 ---

C-- 003B

For NASO model.

2 7 3

4 35

Pin A

Col. L

Sect. 10.0

Pin B

Col. VH

Sect. 3.0

C-- 004

Main cable side.

36 Pin A

Col. L

Sect. 10.0

Pin B

Col. VH

Sect. 3.0

C-- 004

Cab cable side.

37 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

34 Pin

Col.

Sect.

Col.

Sect.

1 2 3 4 5 6 7 8 9 10

L VB CL VN AB GN A AN L H

0.5 0.5 1.0 1.50 1.0 1.0 1.0 1.0 1.0 0.5

11 12 13 14 15 16 17 18 19 20

HN G AV B BG VR C RG VN RH

1.50 0.5 0.5 1.50 1.50 0.5 1.50 1.50 0.5 0.5

For model with cab ISO full optional (main cable side).

C-- 005

5 4 3 2 1

9 8 7 6

20 19 18 17 16 15 14 13 12 11 10 38

Pin 1

Col. L

Sect. 0.5

Pin 11

Col. --

Sect. --

2 3

VB CL

0.5 1.0

12 13

G --

0.5 --

4 5 6

-AB GN

-1.0 1.0

14 15 16

B BG --

1.50 1.50 --

7 8

A AN

1.0 1.0

17 18

C RG

1.50 1.50

1.0

0.5

For model with cab ISO standard (main cable side).

C-- 005

9 8 7 6

5 4 3 2 1

20 19 18 17 16 15 14 13 12 11 10 39

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. L

Sect. 0.5

Pin 11

Col. --

Sect. --

2 3

VB CL

0.5 1.0

12 13

A --

1.0 --

4 5 6

AN AB GN

1.0 1.0 1.0

14 15 16

B BG --

1.50 1.50 --

7 8

AN A

1.0 1.0

17 18

C RG

1.50 1.50

9 10

L H

1.0 0.5

19 20

VN RH

0.5 0.5

For model with cab NASO (main cable side).

C-- 005

5 4 3 2 1

9 8 7 6

20 19 18 17 16 15 14 13 12 11 10 40

Pin 1 2 3 4 5 6

Col. L VB CL VN AB GN

Sect. 0.5 0.5 1.0 1.50 1.0 1.0

Pin 11 12 13 14 15 16

Col. HN G AV B BG VR

Sect. 1.50 0.5 0.5 1.50 1.50 0.5

7 8 9

A AN L

1.0 1.0 1.0

17 18 19

C RG VN

1.50 1.50 0.5

0.5

For model with cab ISO full optional version (cab cable side).

C-- 005

20 19 18 9

17 16 15 14 13 6

12 11 10 4

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

36 Pin 1

Col. L

Sect. 0.5

Pin 11

Col. HN

Sect. 1.50

2 3

VB CL

0.5 1.0

12 13

G --

0.5 --

4 5 6

VN AB GN

1.50 1.0 1.0

14 15 16

B BG --

1.50 1.50 --

7 8

A AN

1.0 1.0

17 18

C RG

1.50 1.50

9 10

L H

1.0 0.5

19 20

VN HR

0.5 0.5

For model with cab ISO standard version (cab cable side).

C-- 005

20 19 18 9

17 16 15 14 13 6

12 11 10 4

Pin 1 2 3 4 5 6

Col. L VB CL AN AB GN

Sect. 0.5 0.5 1.0 1.0 1.0 1.0

Pin 11 12 13 14 15 16

Col. -A -B BG --

Sect. -1.0 -1.50 1.50 --

7 8 9

AN A L

1.0 1.0 1.0

17 18 19

C RG VN

1.50 1.50 0.5

0.5

For model with cab NASO version (cab cable side).

C-- 005

20 19 18 9

17 16 15 14 13 6

12 11 10 4

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin A

Col. N

Sect. 0.5

Pin F

Col. BL

Sect. 0.75

B C

LG G

0.75 0.75

G H

---

D E

V BL

0.75 0.75

J --

---

C-- 005A

D C

B J

F G

44 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. HV

Sect. 1.0

C-- 005B

1 2

45 Pin 1

Col. GL

Sect. 1.0

Pin 2

Col. --

Sect. --

C-- 006

For ISO model (main cable side).

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

38 Pin 1

Col. GL

Sect. 1.0

Pin 2

Col. --

Sect. --

C-- 006

For ISO model (distributor side).

1 2

47 Pin

Col.

Sect.

Col.

Sect.

1 2 3 4 5 6

V S G V -BZ

0.75 0.75 0.75 0.75 -0.75

14 15 16 17 18 19

--HG CN CB --

--0.75 0.75 0.75 --

7 8

---

20 21

BN SN

0.75 0.75

9 10 11 12 13

R -VN ---

0.75 -0.75 ---

22 23 24 25 26

--HV -AR

--0.75 -0.75

C-- 009

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model without cab, standard and full optional, and with cab. ISO full optional version. Pin 1 2 3 4 5 6

Col.

Sect.

Col.

Sect.

V S G V -BZ

0.75 0.75 0.75 0.75 -0.75

14 15 16 17 18 19

--HG CN CB --

--0.75 0.75 0.75 --

7 8

---

20 21

---

9 10 11 12

R -VN --

0.75 -0.75 --

22 23 24 25

--HV --

--0.75 --

0.75

For model with cab, ISO standard version.

84419869A - 06 - 2011

C-- 009

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. V

Sect. 0.75

Pin 14

Col. --

Sect. --

2 3

S G

0.75 0.75

15 16

-HG

-0.75

4 5 6

V -BZ

0.75 -0.75

17 18 19

CN CB --

0.75 0.75 --

7 8

---

20 21

BN NS

0.75 0.75

9 10 11 12

--VN --

--0.75 --

22 23 24 25

--HV --

--0.75 --

0.75

C-- 009

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model without cab, NASO version.

Pin 1 2 3 4 5 6 7 8 9

Col. V S G V -BZ ----

Sect. 0.75 0.75 0.75 0.75 -0.75 ----

Pin 14 15 16 17 18 19 20 21 22

Col. --HG CN CB -BN NS --

Sect. --0.75 0.75 0.75 -0.75 0.75 --

10 11

-VN

-0.75

23 24

-HV

-0.75

12 13

---

25 26

-AR

-0.75

C-- 009

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model with cab, NASO version.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

40 Pin 1

Col. --

Sect. --

Pin 14

Col. --

Sect. --

2 3

-SV

-0.75

15 16

N CB

0.5 0.75

4 5 6

HN CN V

0.75 0.75 0.5

17 18 19

Z BR --

0.5 0.75 --

7 8

-B

-0.75

20 21

LV M

0.75 0.75

9 10 11 12

AN A MN --

0.5 0.5 0.75 --

22 23 24 25

---VR

---0.75

0.75

C-- 010

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model without cab, ISO version

Pin 1 2 3 4 5 6 7 8 9

Col. --SV HN CN V -B AN

Sect. --0.75 0.75 0.75 0.5 -0.75 0.5

Pin 14 15 16 17 18 19 20 21 22

Col. -N CB Z BR G LV M --

Sect. -0.5 0.75 0.5 0.75 0.5 0.75 0.75 --

10 11

A MN

0.5 0.75

23 24

VB --

0.5 --

12 13

-RV

-0.75

25 26

VR --

0.75 --

For model without cab, ISO version.

84419869A - 06 - 2011

C-- 010

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. --

Sect. --

Pin 14

Col. --

Sect. --

2 3

-SV

-0.75

15 16

N CB

0.5 0.75

4 5 6

HN -V

0.75 -0.5

17 18 19

Z BR --

0.5 0.75 --

7 8

-RG

-0.75

20 21

LV M

0.75 0.75

9 10 11 12

--MN --

--0.75 --

22 23 24 25

---VR

---0.75

0.75

C-- 010

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model without cab, standard version NASO.

Pin 1 2 3 4 5 6 7 8 9

Col. --SV HN CN V -RG --

Sect. --0.75 0.75 0.75 0.5 -0.75 --

Pin 14 15 16 17 18 19 20 21 22

Col. -N CB Z BR -LV M --

Sect. -0.5 0.75 0.5 0.75 -0.75 0.75 --

10 11

-MN

-0.75

23 24

---

12 13

-RV

-0.75

25 26

VR --

0.75 --

C-- 010

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model without cab, full optional version NASO.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

42 Pin 1

Col. --

Sect. --

Pin 14

Col. --

Sect. --

2 3

-SV

-0.75

15 16

N CB

0.5 0.75

4 5 6

HN CN V

0.75 0.75 0.5

17 18 19

Z BR G

0.5 0.75 0.5

7 8

-B

-0.75

20 21

LV M

0.75 0.75

9 10 11 12

AN A MN --

0.5 0.5 0.75 --

22 23 24 25

-VB -VR

-0.5 -0.75

0.75

Col. N

Sect. 1.0

C-- 010

2 8

9 10 11 12 13

14 15 16 17 18 19 20 21 22 23 24 25 26

For model with cab, NASO.

Pin 1

Col. L

Sect. 1.0

Pin 2

C-- 010A

1 57

Pin 1 2 3

Col. ----

Sect. ----

Pin 4 5 6

Col. -BL BL

Sect. -0.75 0.75

C-- 011

1 58

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. AN

Sect. 1.0

Pin 4

Col. GN

Sect. 1.0

2 3

B A

1.5 1.0

5 6

R G

1.5 1.5

C-- 012

For ISO model (main cable side).

4 5

59 Pin

Col.

Sect.

Col.

Sect.

1 2 3

G B V

1.0 1.5 1.0

4 5 6

M R N

1.0 1.0 1.5

For ISO model (seven--pole socket side).

C-- 012

5 4

3 1

60 Pin 1 2 3

Col. B N G

Sect. 1.5 1.5 1.0

Pin 4 5 6

Col. R V M

Sect. 1.0 1.0 1.5

C-- 012

For NASO model (main cable side).

4 5

61 Pin 1 2 3

Col. B N G

Sect. 1.5 1.5 1.0

Pin 4 5 6

Col. R V M

Sect. 1.0 1.0 1.5

For NASO model (seven--pole socket side).

C-- 012

6 2

5 4

3 1

62 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

44 Pin

Col.

Sect.

Col.

Sect.

1 2 3

H V M

1.5 1.5 1.5

4 5 6

B -Z

1.5 -1.0

C-- 013

6 63

Pin 1 2 3

Col. H V N

Sect. 1.5 1.5 1.5

Pin 4 5 6

Col. B -Z

Sect. 1.5 -1.0

C-- 013

64 Pin 1 2

Col. R G

Sect. 1.0 0.5

Pin 3 4

Col. N AN

Sect. 1.0 1.0

C-- 020

1 2 3 4

65 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. CN

Sect. 1.0

C-- 024

For model without cab ISO (main cable side).

1 2 66 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

C--024/5

For model without cab ISO (extension side).

1 2

67 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. CN

Sect. 1.0

C-- 025

For model with cab ISO (main cable side).

1 2 68 Pin 1 2

Col. -M

Sect. -1.0

Pin 3 4

Col. RG --

Sect. 0.75 --

C-- 024B

For model without cab NASO.

69 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. CN

Sect. 1.0

C-- 025

For model with and without cab ISO (main cable side).

1 2 70 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

46 Pin

Col.

Sect.

Col.

Sect.

1 2

L N

1.0 1.0

3 --

VG --

1.0 --

C-- 029

71 Pin 1 2

Col. L N

Sect. 1.0 1.0

Pin 3 --

Col. VC --

Sect. 1.0 --

C-- 029A

72 Pin 1 2 3

Col. VN HN A

Sect. 1.5 1.5 1.5

Pin 4 5 6

Col. H A --

Sect. 1.5 1.5 --

C-- 035

For model with cab, full optional version ISO. 2 6

1 5

73 Pin 1

Col. VN

Sect. 1.5

Pin 4

Col. H

Sect. 1.5

2 3

HN A

1.5 1.5

5 6

---

C-- 035

For model with cab, standard version ISO. 2 6

1 5

74 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

H H

1.5 1.5

H --

1.5 --

1.5

2 3

5 6

C-- 035A

6 1

5 4

3 2 75

Pin 1 2 3

Col. --H

Sect. --1.5

Pin 4 5 6

Col. H ---

Sect. 1.5 ---

C-- 035B

6 1

5 4

3 2 76

Pin 1 2 3

Col. H H

Sect. 1.5 1.5

Pin 4 5

Col. H A

Sect. 1.5 1.5

1.5

C-- 035C

6 1

5 4

3 2 77

Pin 1

Col. RN

Sect. 0.5

Pin 4

Col. GR

Sect. 0.5

0.5

C-- 041

3 2 1 78 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

48 Pin

Col.

Sect.

Col.

Sect.

1 2 3

C RG N

1.0 1.0 2.5

4 5 6

AN RB --

2.5 1.5 --

C-- 046

Main cable side.

6 5 4 3 2 1

79 Pin 1 2 3

Col. C RG N

Sect. 1.0 1.0 2.5

Pin 4 5 6

Col. AG RB --

Sect. 2.5 1.5 --

C-- 047

Main cable side.

6 5 4 3 2 1

80 Pin 1 2 3

Col. C RG N

Sect. 1.0 1.0 2.5

Pin 4 5 6

Col. AG RB --

Sect. 2.5 1.5 --

C-- 046 / C-- 047

Fan side.

65 4 3 21

81 Pin 1

Col. C

Sect. 1.0

Pin 4

Col. AG

Sect. 2.5

2 3

RG RB

1.0 1.5

5 --

---

C-- 056

2 1 82 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

C-- 056A

83 Col. Sect. Pin CB--001 ⇒ M--004 1st N 50 ----

Pin Col. Sect. CB--001 ⇒ F--M004/5 1b L 10 2b R 10

CB--001 ⇒ MOD--320 1c R 1.5

BAT--001 ⇒ CB--001 1d N 50

CB-- 001 c

d 84 Pin 1

Col. R

Sect. 16

Pin 1

Col. R

Sect. 16

F--001GH

85 Pin A

Col. B

Sect. 1.0

Pin B

Col. N

Sect. 1.0

LMP-- 014 / LMP-- 015

A 86 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

50 Pin

Col.

Sect.

Col.

Sect.

A B

N H

1.0 1.0

C --

V --

1.0 --

LMP-- 016 / LMP-- 017

For NASO model.

A B C

87 Pin 1 2

Col. N --

Sect. 1.0 --

Pin 3 4

Col. VN H

Sect. 1.0 1.0

LMP-- 016

For ISO model.

88 Pin 1 2

Col. N --

Sect. 1.0 --

Pin 3 4

Col. V H

Sect. 1.0 1.0

LMP-- 017

For ISO model.

89 Pin 1

Col. GN

Sect. 0.5

Pin 3

Col. AN

Sect. 1.0

1.0

LMP-- 018

90 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1 2

-N

-1.0

3 4

-AN

-1.0

LMP-- 018A

91 Pin 1 2

Col. G N

Sect. 0.5 1.0

Pin 3 4

Col. A --

Sect. 1.0 --

LMP-- 019

92 Pin 1 2

Col. -N

Sect. -1.0

Pin 3 4

Col. -A

Sect. -1.0

LMP-- 019A

93 Pin 1

Col. G

Sect. 0.5

Pin 3

Col. AN

Sect. 1.0

1.0

LMP-- 020

For model without cab ISO.

94 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

52 Pin

Col.

Sect.

Col.

Sect.

1 2

R G

1.0 0.5

3 4

N AN

1.0 1.0

LMP-- 020

For model with cab ISO.

95 Pin 1 2

Col. G

Sect. 0.50

Pin 3 4

Col. N R

Sect. 1.0 1.0

LMP-- 020A

For model without cab NASO.

96 Pin 1 2

Col. R G

Sect. 1.0 0.5

Pin 3 4

Col. N --

Sect. 1.0 --

LMP-- 020A

For model with cab NASO.

97 Pin 1

Col. R

Sect. 1.0

Pin 3

Col. N

Sect. 1.0

0.5

1.0

LMP-- 020C

98 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1 2

GN N

0.5 1.0

3 4

A R

1.0 1.0

LMP-- 021

For model without cab ISO.

99 Pin 1 2

Col. R GN

Sect. 1.0 0.5

Pin 3 4

Col. N A

Sect. 1.0 1.0

LMP-- 021

For model with cab ISO.

100 Pin 1 2

Col. GN --

Sect. 0.5 --

Pin 3 4

Col. N R

Sect. 1.0 1.0

LMP-- 021A

For model without cab NASO.

101 Pin 1

Col. R

Sect. 1.0

Pin 3

Col. N

Sect. 1.0

0.5

LMP-- 021A

For model with cab NASO.

102 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

54 Pin

Col.

Sect.

Col.

Sect.

0.5

LMP--028

12 103 Pin 1

Col. H

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 030

1 104

Pin 1

Col. BV

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 030A

1 105

Pin 1

Col. H

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 031

1 106

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

LMP-- 032

1 107

Pin 1

Col. AB

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 033

1 108

Pin 1 1

Col. GR N

Sect. 0.5 0.5

Pin 1 --

Col. N --

Sect. 0.5 --

LMP-- 034

109 Pin 1

Col. G

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

LMP-- 036

1 110 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

56 Pin

Col.

Sect.

Col.

Sect.

0.5

LMP-- 037

1 111

Pin 1

Col. GN

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

LMP-- 038

1 112

Pin 1

Col. GN

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

LMP-- 042

113 Pin 1

Col. AN

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 048

1 114

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

LMP-- 049

1 115

Pin 1

Col. A

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 050

1 116

Pin 1

Col. A

Sect. 1.5

Pin 2

Col. N

Sect. 1.0

LMP-- 051

1 117

Pin 1

Col. LN

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

LMP-- 054

1 118 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

58 Pin

Col.

Sect.

Col.

Sect.

1.0

LMP-- 055

1 119

Pin A

Col. N

Sect. 1.0

Pin B

Col. R

Sect. 1.0

LMP-- 056

For model without cab ISO version.

120 Pin Col. Sect. C--001 A1 ⇒ M--004 1st RN 2.5 M--004 ⇒ ALT--001 1c R 16

Pin Col. Sect. CB--001 ⇒ M--004 1b N 50 -----

M-- 004 b a c 121

Pin 1

Col. N

Sect. 1.0

Pin 2

Col. AB

Sect. 1.0

M-- 007

122 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

M-- 008

123

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

60 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

L L

1.5 1.5

2B 3B

C AB

1.5 1.5

4A. 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

ZB M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M -M M

1.0 -1.0 1.5

9B 10B 11B 12B

SG -HL C

1.0 -1.0 1.5

13A 14A 15A 16A

M L M B

1.0 0.75 0.75 0.75

13B 14B 15B 16B

LR BL LG G

1.0 0.75 0.75 0.75

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

B B -L M --L M L M --

1.0 1.5 -0.75 1.0 --1.0 1.0 1.0 1.5 --

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

GN G -LV MH --ZC BV GR BG --

1.0 1.5 -0.75 1.0 --1.0 1.0 1.0 1.5 --

29A 30A

---

29B 30B

---

31A 32A

M --

4.0 --

31B 32B

M --

4.0 --

For model without cab full optional version ISO.

84419869A - 06 - 2011

MOD--001A

124

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

L L

1.5 1.5

2B 3B

C AB

1.5 1.5

4A. 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

ZB M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M -M M

1.0 -1.0 1.5

9B 10B 11B 12B

SG -HL C

1.0 -1.0 1.5

13A 14A 15A 16A

M L M B

1.0 0.75 0.75 0.75

13B 14B 15B 16B

LR BL LG G

1.0 0.75 0.75 0.75

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

B B -L ---L -L M --

1.0 1.5 -0.75 ---1.0 -1.0 1.5 --

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

GN G -LV ---ZC -GR BG --

1.0 1.5 -0.75 ---1.0 -1.0 1.5 --

29A 30A

---

29B 30B

---

31A 32A

---

31B 32B

---

MOD--001A

125

For model without cab ISO standard version.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

62 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

L L

1.5 1.5

2B 3B

C AB

1.5 1.5

4A 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

ZB M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M M M M

1.0 1.5 1.0 1.5

9B 10B 11B 12B

SG BL HL C

1.0 1.5 1.0 1.5

13A 14A 15A 16A

M L M B

1.0 0.75 0.75 0.75

13B 14B 15B 16B

LR BL LG G

1.0 0.75 0.75 0.75

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

B B M L MH -C L M L ---

1.0 1.5 1.5 0.75 0.75 -0.75 1.5 1.0 1.0 ---

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

GN G BG LV M -M ZC VG AG ---

1.0 1.5 1.5 0.75 0.75 -0.75 1.5 1.0 1.0 ---

29A 30A

---

29B 30B

---

31A 32A

M A

6.0 6.0

31B 32B

M L

6.0 6.0

For model with cab, full optional version ISO.

84419869A - 06 - 2011

MOD--001A

126

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

L L

1.5 1.5

2B 3B

C AB

1.5 1.5

4A 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

ZB M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M M M M

1.0 1.5 1.0 1.5

9B 10B 11B 12B

SG BL HL C

1.0 1.5 1.0 1.5

13A 14A 15A 16A

M L M B

1.0 0.75 0.75 0.75

13B 14B 15B 16B

LR BL LG G

1.0 0.75 0.75 0.75

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

B B M L --C L M L ---

1.0 1.5 1.5 0.75 --0.75 1.5 1.0 1.0 ---

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

GN G BG LV --M ZC VG AG ---

1.0 1.5 1.5 0.75 --0.75 1.5 1.0 1.0 ---

29A 30A

---

29B 30B

---

31A 32A

-A

-6.0

31B 32B

-L

-6.0

MOD--001A

127

For model with cab, standard version ISO.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

64 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

-L

-1.5

2B 3B

-AB

-1.5

4A 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

BL M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M -M M

1.0 -1.0 1.5

9B 10B 11B 12B

SG -HL C

1.0 -1.0 1.5

13A 14A 15A 16A

M -M B

1.0 -0.75 0.75

13B 14B 15B 16B

LR -LG G

1.0 -0.75 0.75

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

B B -L ---L M -M --

1.0 1.5 -0.75 ---1.0 1.0 -1.5 --

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

GN N -LV ---ZC BV -BG --

1.0 1.5 -0.75 ---1.0 1.0 -1.5 --

29A 30A

---

29B 30B

---

31A 32A

M --

6.0 --

31B 32B

M --

6.0 --

For model without cab, full optional version NASO.

84419869A - 06 - 2011

MOD--001A

128

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

-L

-1.5

2B 3B

-AB

-1.5

4A 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

BL M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M -M M

1.0 -1.0 1.5

9B 10B 11B 12B

SG -HL C

1.0 -1.0 1.5

13A 14A 15A 16A

M -M B

1.0 -0.75 0.75

13B 14B 15B 16B

LR -LG G

1.0 -0.75 0.75

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

B B -L ---L --M --

1.0 1.5 -0.75 ---1.5 --1.5 --

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

GN N -LV ---ZC --BG --

1.0 1.5 -0.75 ---1.5 --1.5 --

29A 30A

---

29B 30B

---

31A 32A

M --

6.0 --

31B 32B

M --

6.0 --

MOD--001A

129

For model without cab, standard version NASO.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

66 Pin 1A

Col. L

Sect. 1.5

Pin 1B

Col. ZN

Sect. 1.5

2A 3A

-L

-1.5

2B 3B

-AB

-1.5

4A 5A 6A

M M L

1.5 0.75 1.5

4B 5B 6B

ZB M HN

1.5 0.75 1.5

7A 8A

L H

1.5 0.75

7B 8B

VN Z

1.5 0.75

9A 10A 11A 12A

M M M M

1.0 1.5 1.0 1.5

9B 10B 11B 12B

SG BL HL C

1.0 1.5 1.0 1.5

13A 14A 15A 16A

M L M B

1.0 0.75 0.75 0.75

13B 14B 15B 16B

LR BL LG G

1.0 0.75 0.75 0.75

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

B B M L --C L M L ---

1.0 1.5 1.5 0.75 --0.75 1.5 1.0 1.0 ---

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

GN G BG LV --M ZC VG AG ---

1.0 1.5 1.5 0.75 --0.75 1.5 1.0 1.0 ---

29A 30A

---

29B 30B

---

31A 32A

M A

6.0 6.0

31B 32B

M L

6.0 6.0

For model with cab, NASO version.

84419869A - 06 - 2011

MOD--001A

130

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin Col. RLY--MR1

Sect.

Pin Col. RLY--27

Sect.

30 85

RN HR

2.5 0.75

30 85

N N

0.75 0.5

86 87 87A

Z L --

0.50 4.0 --

86 87 87A

H HR --

0.5 0.75 --

RLY--25 30

RLY--28 30

85 86 87 87A

-----

85 86 87 87A

-----

MOD--001B

RLY--26 30 85 86

----

87 87A

---

For model without cab.

131

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

68 Pin Col. RLY--MR1

Sect.

Pin Col. RLY--27

Sect.

30 85

RN HR

2.5 0.75

30 85

N N

0.75 0.5

86 87 87A

Z L --

0.50 2.5 --

86 87 87A

H HR --

0.5 0.75 --

RLY--25 30

RLY--28 30

85 86 87 87A

-----

85 86 87 87A

-----

6.0 0.5 0.5

----

6.0 --

---

RLY--26 30 A 85 N 86 RH 87 87A

A --

MOD--001B

For model with cab

132

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 33A

Col. --

Sect. --

Pin 33B

Col. --

Sect. --

34A 35A

---

34B 35B

---

36A RLY--1 30

1.5

36B RLY--5 30

85 86

N HN

0.5 0.5

85 86

---

87 87A RLY--2 30

H --

1.5 --

---

2.5

87 87A RLY--6 30

85 86 87 87A

N BR B --

0.5 0.5 1.5 --

85 86 87 87A

-----

C N GR R C

1.0 0.5 0.5 1.5 1.0

------

RLY--3 30 85 86 87 87A RLY--4 30 85 86 87 87A

VN N VN V --

1.5 0.5 0.5 1.5 --

MH GV MH GL --

1.0 1.0 1.0 1.0 --

RLY--7 30 85 86 87 87A RLY--8 30 85 36 37 37A

MOD--001C

133

For model without cab, full optional version ISO.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

70 Pin 33A

Col. --

Sect. --

Pin 33B

Col. --

Sect. --

34A 35A

---

34B 35B

---

36A RLY--1 30

1.5

36B RLY--5 30

1.5

85 86

N HN

0.5 0.5

85 86

AV H

0.5 0.5

87 87A RLY--2 30

H --

1.5 --

HN H

1.5 1.5

2.5

87 87A RLY--6 30

1.5

85 86 87 87A

N BR B --

0.5 0.5 1.5 --

85 86 87 87A

VR V VN V

0.5 0.5 1.5 1.5

C N GR R C

1.0 0.5 0.5 1.5 1.0

AG N CB L --

1.0 0.5 0.75 1.0 --

RLY--3 30 85 86 87 87A RLY--4 30 85 86 87 87A

VN N VN V --

1.5 0.5 0.5 1.5 --

MH GV MH GL --

1.0 1.0 1.0 1.0 --

RLY--7 30 85 86 87 87A RLY--8 30 85 36 37 37A

For model with cab, full optional version ISO.

84419869A - 06 - 2011

MOD--001C

134

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 33A

Col. --

Sect. --

Pin 33B

Col. --

Sect. --

34A 35A

---

34B 35B

---

36A RLY--1 30

1.5

36B RLY--5 30

85 86

N HN

0.5 0.5

85 86

---

87 87A RLY--2 30

H --

1.5 --

---

2.5

87 87A RLY--6 30

85 86 87 87A

N BR B --

0.5 0.5 1.5 --

85 86 87 87A

-----

C N GR R C

1.0 0.5 0.5 1.5 1.0

------

RLY--3 30 85 86 87 87A RLY--4 30 85 86 87 87A

VN N VN V --

1.5 0.5 0.5 1.5 --

------

RLY--7 30 85 86 87 87A RLY--8 30 85 36 37 37A

MOD--001C

135

For model without cab, full optional NASO and standard ISO version.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

72 Pin 33A

Col. --

Sect. --

Pin 33B

Col. --

Sect. --

34A 35A

---

34B 35B

---

36A RLY--1 30

1.5

36B RLY--5 30

85 86

N HN

0.5 0.5

85 86

---

87 87A RLY--2 30

H --

1.5 --

---

2.5

87 87A RLY--6 30

85 86 87 87A

N BR B --

0.5 0.5 1.5 --

85 86 87 87A

-----

C N GR R --

1.0 0.5 0.5 1.5 --

------

RLY--3 30 85 86 87 87A RLY--4 30 85 86 87 87A

VN N VN V --

1.5 0.5 0.5 1.5 --

------

RLY--7 30 85 86 87 87A RLY--8 30 85 36 37 37A

For model without cab, standard version NASO.

84419869A - 06 - 2011

MOD--001C

136

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 33A

Col. --

Sect. --

Pin 33B

Col. --

Sect. --

34A 35A

---

34B 35B

---

36A RLY--1 30

1.5

36B RLY--5 30

85 86

N HN

0.5 0.5

85 86

---

87 87A RLY--2 30

H --

1.5 --

---

2.5

87 87A RLY--6 30

85 86 87 87A

N BR B --

0.5 0.5 1.5 --

85 86 87 87A

-----

C N GR R C

1.0 0.5 0.5 1.5 1.0

AG N CB L --

1.0 0.5 0.75 1.0 --

RLY--3 30 85 86 87 87A RLY--4 30 85 86 87 87A

VN N VN V --

1.5 0.5 0.5 1.5 --

------

RLY--7 30 85 86 87 87A RLY--8 30 85 36 37 37A

MOD--001C

137

For model with cab, standard ISO and NASO version.

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

74 Pin F--1c

Col.

Sect.

Col.

Sect.

1A F--2c

1.5

2A F--3c 3A

1.5

2.0

4.0

3.0

2.5

1.5 0.5 0.5

RLY--3c 30 85 86

----

F--4c 4A. F--5c 5A F--6c 6A

RLY--1c 30 AB 85 N 86 BG 87 AB 87A -RLY--2c 30 L 85 N 86 BG 87 R 87A --

1.5 --

---

6.0 0.5 0.5 6.0 --

87 87A RLY--4c 30 85 86 87 87A

AN N VB A --

1.5 0.5 0.5 1.5 --

Col.

Sect.

Col.

Sect.

6.0

F--003 A

MOD--002

138

MOD--003

139

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin F--004

Col.

Sect.

Col.

Sect.

10.0

MOD--3/4

For model without cab.

140

Col. Pin F--M004 A R F--M005 A L

Sect.

Col.

Sect.

MOD--3/4

For model with cab

141

Pin 2

Col. BR

Sect. 1.0

Pin 6

Col. N

Sect. 1.0

4 5

CB BL

0.75 1.0

8 --

CN --

0.75 --

MOD--004 6 5

142

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

76 Pin A1

Col. C

Sect. 4.0

Pin B5

Col. CN

Sect. 0.75

A2 A3

A V

1.0 1.0

B6 B7

LN L

1.0 1.0

A4 A5 A6

AN G MV

1.0 1.0 1.0

B8 C1 C2

N ---

2.5 ---

A7 A8

CB BL

0.75 0.75

C3 C4

---

B1 B2 B3 B4

C V VB BR

4.0 1.0 1.0 1.0

C5 C6 C7 C8

-----

MOD--004A

C8 C7 C6 C5 C4 C3 C2 C1

For NASO model.

B8 B7 B6 B5 B4 B3 B2 B1 A8 A7 A6 A5 A4 A3 A2 A1

143 Pin 1 2 3 4 5 6

Col. -C N --L

Sect. -0.5 0.5 --0.5

Pin 8 9 10 11 12 13

Col. BR BN ---H

Sect. 0.5 0.5 ---0.5

0.5

MOD--045

14 7

8 1

144 Pin 1

Col. R

Sect. 1.5

Pin 2

Col. R

Sect. 1.5

MOD--320

145

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 86--1a

Col. AR

Sect. 0.75

Pin 85--2a

Col. N

Sect. 0.75

30--b

87--c

RLY--001GH

146 Pin

Col.

Sect.

Col.

Sect.

RES--001

147 RES--022 Pin Col. 1 N LMP--023 Pin Col. 1 GN

Sect. 1.0

Pin 2

Col. ZC

Sect. 1.0

Sect. 0.5

Pin --

Col. --

Sect. --

RES-- 022 LMP-- 023

2 1 148 RES--039 Pin Col. 1 N LMP--040 Pin Col. 1 GN

Sect. 1.0

Pin 2

Col. ZC

Sect. 1.0

Sect. 0.5

Pin --

Col. --

Sect. --

RES-- 039 LMP-- 040

2 1 149 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

78 Pin

Col.

Sect.

Col.

Sect.

1 2 3

C RG RB

1.0 1.0 1.5

4 5 --

AG ---

2.5 ---

RES-- 093

1 2 3 4 5

150 Pin 1

Col. H

Sect. 0.75

Pin 2

Col. HG

Sect. 0.75

SEN-- 002

1 151

Pin 1

Col. MH

Sect. 0.75

Pin 1

Col. HV

Sect. 0.75

SEN-- 003

152 Pin 1

Col. S

Sect. 1.0

Pin 2

Col. ZB

Sect. 1.0

SEN-- 004

1 153

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

SEN-- 004A

154 Pin 1

Col. HV

Sect. 0.75

Pin 2

Col. HG

Sect. 0.75

SEN-- 005

1 155

Pin 1 2

Col. MN ZC

Sect. 0.75 0.75

Pin 3 --

Col. LR --

Sect. 0.75 --

SEN-- 006

3 2 1

156 Pin A

Col. VN

Sect. 0.75

Pin B

Col. ZC

Sect. 0.75

SEN-- 008

B C 157 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

80 Pin

Col.

Sect.

Col.

Sect.

0.75

SEN-- 009

1 2 158 Pin 1 2

Col. HV ZC

Sect. 0.75 0.75

Pin 3 --

Col. ---

Sect. ---

SEN-- 009A

3 2 1

159 Pin 1 2

Col. LG VA

Sect. 1.0 1.0

Pin 3 --

Col. N --

Sect. 1.0 --

SEN-- 010

3 2 1

160 Pin 1

Col. MH

Sect. 0.75

Pin 1

Col. N

Sect. 1.0

SEN-- 012

161 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin 1

Col. H

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

SEN-- 031

1 162

Col.

Sect.

Col.

Sect.

1 2

VN B

0.5 0.75

3 --

N --

0.5 --

SEN-- 044

3 2 1 163 Pin 1

Col. GL

Sect. 1.0

Pin --

Col. --

Sect. --

SOL-- 001

164 Pin 1

Col. N

Sect. 1.0

Pin 2

Col. CN

Sect. 1.0

SOL-- 002

1 165 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

82 Pin

Col.

Sect.

Col.

Sect.

1.0

SOL-- 005

166 Pin 1 2 3

Col. BV C BR

Sect. 0.5 0.5 0.5

Pin 4 5 6

Col. BL -BN

Sect. 0.5 -0.5

SOL-- 043

3 2 1 6 5 4

167 Pin 1

Col. GV

Sect. 1.0

Pin 2

Col. N

Sect. 1.0

SW-- 001

1 2

168 Pin 1

Col. ZB

Sect. 1.5

Pin 5

Col. BL

Sect. 1.0

2 3

BR C

1.0 1.5

6 7

AN A

1.0 1.5

1.0

SW-- 002 3 4

For ISO model.

5 6

7 169

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1 2 3 4

-C BR --

-1.0 1.0 --

5 6 7 --

-MV N --

-1.0 1.0 --

SW-- 002A 3 4

For NASO model.

5 6

7 170

Pin 1 2 3

Col. Z ZN BR

Sect. 1.0 1.5 0.5

Pin 5 6 7

Col. HN BL AN

Sect. 0.5 1.0 1.0

0.5

1.0

SW-- 003

8 3

171 Pin 1

Col. HV

Sect. 0.75

Pin 2

Col. HG

Sect. 0.75

SW-- 005

1 172

Pin 1

Col. N

Sect. 1.0

Pin 3

Col. --

Sect. --

1.0

SW-- 005A

173 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

84 Pin

Col.

Sect.

Col.

Sect.

0.75

SW-- 006

1 174

Pin 1

Col. HN

Sect. 0.75

Pin --

Col. --

Sect. --

SW-- 007

175 Pin 1

Col. SG

Sect. 1.0

Pin 2

Col. V

Sect. 1.0

SW-- 008

1 176

Pin 1

Col. BR

Sect. 0.75

Pin 2

Col. LR

Sect. 0.75

SW-- 011

177 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 SW--013 Pin Col. 1 -2 -3 CN 4 GR LMP--014A Pin Col. 1 GN

Sect. --1.0 1.0

Pin 5 6 7 8

Col. --CB GR

Sect. --1.0 1.0

Sect. 0.5

Pin 2

Col. N

Sect. 1.0

For model with cab

SW-- 013

LMP-- 014A

178

SW--013 Pin Col. 1 GN 2 CR LMP--014A Pin Col. 1 GN

Sect. 1.0 1.0

Pin 5 6

Col. ---

Sect. ---

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

For model without cab.

SW-- 013

LMP-- 014A

179

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

86 SW--015 Pin Col. 1 2

Sect.

Col.

Sect.

1.0 1.0

5 6

---

Sect. 0.5

Pin 2

Col. N

Sect. 1.0

CL VG

LMP--016A Pin Col. 1 GN

SW-- 015

LMP-- 016A

180

SW--023 Pin Col. 1 -2 VG 3 L 4 -LMP--029 Pin 1

Col. GN

Sect. -1.0 1.0 --

Pin 5 6 7 8

Col. --VG AB

Sect. --1.0 1.0

Sect. 0.5

Pin 2

Col. N

Sect. 1.0

SW-- 017

LMP-- 018C

181

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

0.5

SW-- 019

182

Pin HL

Col.

Sect.

Col.

Sect.

0.5

1.5

R W

BG B

0.5 1.5

B2 --

GN --

0.5 --

SW-- 020

HL T

B1 R

B2 183

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

88 SW--020A Pin Col.

Sect.

Col.

Sect.

BG B

1.5 1.50

3 4

---

LMP--020B Pin Col. 1 GN

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

1 2

For model without cab.

SW-- 020A

LMP-- 020B

184

SW--021 Pin Col. 1 -2 C LMP--022 Pin Col. 1 GN

Sect. -1.0

Pin 3 4

Col. CN --

Sect. 1.0 --

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

SW-- 021 1

LMP-- 022 1

185

84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 SW--023 Pin Col. 1 2

-N

3 VR 4 -LMP--029 Pin 1

Col. GN

Sect.

Col.

Sect.

-0.5

5 6

N AV

0.5 0.5

0.5 --

7 8

---

Sect. 0.5

Pin 2

Col. AV

Sect. 1.0

SW-- 023

LMP-- 029

186

Pin 1 2 3

Col. -B BL

Sect. -0.75 0.75

Pin 4 5 --

Col. ----

Sect. ----

For ISO model.

SW-- 024

5 4

187

Pin 1

Col. B

Sect. 0.75

Pin 2

Col. LH

Sect. 0.75

SW-- 024A

For model with cab NASO.

1 188 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

90 Pin

Col.

Sect.

Col.

Sect.

1 2

CN GR

0.5 0.5

3 4

R RN

0.5 0.5

SW-- 026

Valid for model with cab and without cab, ISO standard and full optional and NASO full optional.

189 Pin 1 2

Col. -RN

Sect. -0.5

Pin 3 4

Col. C --

Sect. ---

SW-- 026

For model without cab, standard NASO.

190 Pin 1 2

Col. GR R

Sect. 0.5 0.5

Pin 3 4

Col. R RN

Sect. 0.5 0.5

SW-- 027

Valid for model with cab and without cab, ISO standard and full optional and NASO full optional.

191 Pin 1

Col. VG

Sect. 0.5

Pin 3

Col. --

Sect. --

0.5

SW-- 028

4 3 2 1

192 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 Pin

Col.

Sect.

Col.

Sect.

1.0

SW-- 028A

193 Pin 1 2 3

Col. VG C RG

Sect. 3.0 1.5 1.5

Pin 4 5 --

Col. VH HR --

Sect. 3.0 1.0 --

SW-- 030

1 2 3 4 5

194 SW--032 Pin Col. 1 BN 2 N 3 N LMP--033A Pin 1

Col. G

SW-- 032

Sect. 0.75 0.75

Pin 4 5

Col. NS --

Sect. 0.75 --

0.75

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

For model without cab.

LMP-- 033A

195 84419869A - 06 - 2011

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

92 SW--032 Pin Col. 1 SN 2 N 3 N LMP--033A Pin Col. 1 G

Sect. 0.75 0.75 0.75

Pin 4 5 6

Col. BN ---

Sect. 0.75 ---

Sect. 0.5

Pin 2

Col. N

Sect. 0.5

For model with cab

SW-- 032

LMP-- 033A

196 Pin 50 15B

Col.

Sect.

Col.

Sect.

H M

0.75 2.5

15A 30

M L

2.5 4.0

SW-- 715

197

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

SECTION 90 -- CAB Chapter 1 -- Cab CONTENTS

Operation

Description

Page

90 100 22

Bonnet. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

90 150 10

Cab with platform assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

90 160 15

Cab right--hand pillar guard. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

90 160 34

Cab right--hand upper guard. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

90 160 42

Cab right--hand mudguard guard. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

90 160 17

Cab left--hand upper guard. Removal--Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

90 156 14 e 90 156 28 Cab windows (Replacing glued cab windows) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

OP. 90 100 22 BONNET R.I

Removal

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows: 1. Disconnect the electrical connections (3) of the front headlamps. 2. Remove the retaining bolts holding the pivot bracket (1) to the base support. 3. Remove the spring clamp of the lower pivot strut (2) and detach the bonnet from the tractor and rest it on a suitable support. Installation Proceed as follows:

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

4. Position the bonnet on the relative bracket, insert the strut (2,fig. 1) on the lower pivot and lock it with the spring clamp. 5. Fit the pivot bracket (1,fig. 1) on the base support and lock the retaining bolts. 6. Disconnect the electrical connections (3) of the front headlamps.

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

Op. 90 150 10 CAB ASSEMBLY WITH PLATFORM Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

Proceed as follows.

1. Unscrew the fixing screws (1) and remove the front wheel mudguards (if applicable). Do this on both sides. 2 2. Carry out operation 90 100 22 -- Bonnet (only removal).

3. Detach the side panel (1). Do this on both sides.

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

4. Connect the connections (1 and 2), of the recovery station 380000315, to the appropriate connections on the cab air--conditioning system pipes and drain off the refrigerant from the system.

4 5. Loosen the clamp, detach the sleeve (1) from the radiator and drain off the coolant. 6. Carry out operation 10 216 40 -- Fuel tank (perform removal only). 7. Set a stand under the rear transmission and detach the rear right wheel.

5 8. Unscrew the bottom nut of the cab rear fixing screw (2). Do this on both sides. 9. Disconnect the cab ground (1).

6 10. Unscrew the relevant fixing screws, detach the footrest (1), lift the front part of the mat (2) and unscrew the cab front fixing nut. Do this on both sides.

7 84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

11. Disconnect the parking brake tie--rod (1) (ISO version). 12. Unscrew the retaining bolts and detach the fuel tank support rear bracket (2).

8 13. Remove the creeper unit tie--rod (1) and disconnect the service brake line (2). 14. Detach the synchronized power take off tie--rod.

9 15. Disconnect the connection (1) of the rear transmission, the connection of the seven--pole power socket and any others that may be present.

10 16. Remove the tie--rod (2) of the three--point linkage.

11 84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

17. Disconnect the link rods (1) from the auxiliary control valves.

12 18. Disconnect the rear hydraulic lift control tie--rods (1 and 2) and the one for ground operation (3).

13 19. Disconnect the differential lock control rod (1). 20. Disconnect the transmission link rods (2). 21. Disconnect the parking brake tie--rod (3) (ISO version). 22. Disconnect the range gear link rods (4). 23. Disconnect the service brake piping (5).

14 24. Disconnect the central auxiliary control valve link rods (1).

15 84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

25. Disconnect the power steering return pipe (1).

16 26. Disconnect the pipes (1) of the cab heater. 27. Disconnect these pipes: (2) for steering cylinder control and (3) for power steering supply.

17 28. Disconnect the electrical connection (1) from the brake fluid tank. 29. Disconnect the cab air--conditioning system pipes (2).

18 30. Disconnect the throttle link rod (1) from the injection pump.

19 84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

31. Disconnect the electrical connections: (1) for start control and (2) general engine.

20 32. Unscrew the retaining bolts and detach the fuel tank support front bracket (2).

21 33. Unscrew the relevant screws and detach the cover (1), disconnect the reverser and transmission clutch drive link rods.

22 34. Position tool 380000294 (1) inside the cab (cab centre line) and, by means of a hoist and nylon sling (2), lift the cab, making sure that all parts are disconnected and there is no sticking. Check that the doors are locked in the open position, to prevent contact between the windows and the tool 380000294. 35. Position the cab on a suitable support.

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

36. To re--fit the cab, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. ---

Using a hoist, nylon sling and tool 380000294 position the cab on the tractor. Tighten the cab fixing screws to a torque of 200 Nm (20.4 kgm) keeping to the following tightening sequence. 27672

NOTE: Cab fixing nut tightening sequence. 1 st phase: front right nut; 2 nd phase: rear left nut; 3 rd phase: front left nut; 4 th phase: rear right nut; -------------------

Connect the reverser and transmission clutch drive link rods. Position and secure the fuel tank support front bracket. Connect the general engine and start control electric connections. Connect the throttle control tie rod. Connect the cab air--conditioning system pipes. Connect the electrical connection to the brake fluid tank. Connect the power steering supply pipe. Connect the steering cylinder control piping. Connect the pipes of the cab heater. Connect the power steering return pipe. Connect the central auxiliary control valve tie rods. Connect the right--hand service brake control pipe. Connect the range gear link rods. Connect the parking brake right--hand tie--rod. Connect the transmission link rods. Connect the differential lock control rod. Connect the rear hydraulic lift control tie--rods and the related ground control. Connect the rear auxiliary control valve tie rods.

---------------------

23 Position and secure the link rod of the three--point linkage. Connect the electrical connections of the rear transmission, seven--pole power socket and any others that may be present. Connect the tie--rod controlling the power take--off synchronized with the transmission. Connect the left--hand service brake control pipe. Connect the creeper unit control rod. Position the fuel tank support rear bracket. Connect the left parking brake tie--rod. Put in the cab mat, position the footrest and secure it. (Do this on both sides). Connect the cab ground. Position and secure the right--hand rear wheel. Carry out operation 10 216 40 -- Fuel tank (perform installation only). Remove the wooden chocks for locking the front axle. Position the sleeve on the engine radiator and secure it. Connect the charging station 380000315 to the appropriate connections and charge the cab air--conditioning system. Install the side panels (do this on both sides). Carry out operation 90 100 22 -- Bonnet (only installation). Position and secure the front wheel mudguards, if applicable (carry out this operation on both sides). Fill up the engine cooling system (see page 6, sect. 0 for prescribed product and quantity). Bleed the brakes and check the level of the liquid in the brake fluid tank (see page 6, sect. 00 for the prescribed product and quantity). Perform cab air--conditioning system functional testing.

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

Op. 90 160 15 CAB RIGHT--HAND PILLAR GUARD Removal--Installation

2. Remove the electrical connections (1). 3. Remove the control knobs (1, fig. 24): ventilator, cab air--conditioning system and heater. 4. To refit the RH mudguard proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Insert the control knobs: ventilator, air--conditioning system and heater.

Connect the electrical connections:

Position and secure the right--hand guard on the pillar.

84419869A - 06 - 2011

cab 25

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

Op. 90 160 34 CAB RIGHT--HAND TOP GUARD Removal--Installation

3. Disconnect the electrical connections (1) and remove the right--hand top guard. 4. To refit the RH mudguard proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Connect the electrical connections.

Position and secure the right--hand top guard.

Fit the knob on the PTO control lever.

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

Op. 90 160 42 CAB RIGHT--HAND MUDGUARD GUARD Removal--Installation

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Carry out operation 90 160 34 -- Cab right--hand top guard (perform removal only) 2. Unscrew the retaining bolts and remove the footrest (1). Do this on both sides. Remove the mat (2). 3. Detach the knob (1) from the throttle control lever.

4. Unscrew the relevant screws fastening the mudguard guard.

29 5. Unscrew the relative retaining bolts and detach the air filter grille (1). 6. Unscrew the air filter support fixing screws, lift the guard (2) and disconnect the electric connections. 7. Take off the guard (2). 8. To refit the RH mudguard proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Connect the electric connections right--hand mudguard guard.

Position and secure the air cleaner support.

Position and secure the air cleaner grille.

Position and secure the RH mudguard guard.

84419869A - 06 - 2011

to the

30 ----

Fit the knob on the throttle control lever. Position the cab mat and secure it using the two footrests. Carry out operation 90 150 00 -- Cab right--hand top guard (perform installation only)

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

Op. 90 160 17 CAB LEFT--HAND TOP GUARD Removal--Installation

2. This operation enables getting into the fuse and relay box (2). 3. To refit the LH mudguard proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Position and secure the left--hand top guard. 32

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

OP. 90 156 14 -- 90 156 28 CAB WINDOWS Replacement of glued cab windows Removal

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows. 1. Thread the cutting wire (1, fig. 33) into the tool and lock in position. 2. From inside the cab push the cutting wire (1, fig. 33 ) through the adhesive (2) between the window and its surround.

27870

33 3. Secure the wire (1, fig. 34) to the handgrip (2).

27871

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

4. Lock the tool on the adhesive (see fig. A). Keep the wire close to the window and pull on the handgrip (2, fig. 35). 5. Repeat this operation until the window is completely detached. Make long cuts on straight sections and short cuts around corners to prevent the window from breaking. 6. Using suction cups, remove the window and place on a suitable surface to avoid damage. 27872

35 7. Using a spatula, remove all the adhesive (1) from the window surround, taking care to cause no damage. 8. Remove the adhesive from the window as described in the previous operation. NOTE: When replacing a broken window: remove any fragments still attached to the cab and carry out operations no. 1 -- 8. 9. Clean the window surround using a suitable solvent.

27873

Re--fitting the window Proceed as follows. 1. Make sure that the contact area between the window and its surround is perfectly clean. 2. Apply the glass activator VP 04604 GURIT ESSEX on the edge of the window (contact area with the adhesive) using the applicator supplied (see fig. 37) and dry thoroughly with a dry cloth. 27874

84419869A - 06 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 1

3. Apply the glass primer Betaprime 5100 GURIT ESSEX on the edge of the window (contact area with the adhesive) using the applicator supplied and leave to dry thoroughly (> 30 seconds).

4. Apply the metal plate primer Beta Wipe 5402 GURIT ESSEX on the window surround (contact area with the adhesive) using the applicator supplied and leave to dry thoroughly.

5. Cut the spout on the adhesive dispenser as shown in fig. 38 to obtain a triangular cross--section bead.

6. Apply a bead of polyurethane based Betaseal 7120 GURIT ESSEX on the window (the cross--section of the bead must be triangular, with a base of 10 mm and a height of 12 รท 15 mm).

NOTE: Make sure that there are no areas where adhesive is missing, otherwise water may penetrate.

7. Insert the window support blocks, if present. 8. Using suction cups, position the window and its surround and use clamps to apply uniform pressure, providing a 4 mm thickness of adhesive and to ensure perfect adhesion.

NOTE: Leave the clamps in place for 4 hours until the adhesive has completely polymerized. It takes 48 hours for the adhesive to polymerize definitively. To ensure efficient bonding, do not move the cab or tractor during this period.

84419869A - 06 - 2011

7.0 3.0

27875

PRINT NO. 84419869A1 1st Service Manual Update mod. POWERSTAR T4.55 -- T4.65 -- T4.75 -- Print No. 84419869A IMPORTANT NOTES These pages replace the corresponding pages in the Manual of mod. POWERSTAR T4.55 -- T4.65 -- T4.75 -- contents pages 3, 4, 5, 6, 7 and 8 -- sect. 33, chap. 1, pages 1 and 2

-- sect. 35, chap. 1, pages 1 to 24

IMPORTANT NOTES The following pages are newly issued: -- sect. 33, chap. 1, pages 13 to 16 -- sect. 35, chap. 1, pages 25 to 28 - sect. 35, chap. 5, pages 1 to 4

- sect. 44, chap. 1, pages 1 to 22 - sect. 90, chap. 2, pages 1 to 16

Print no. 84419869A1 -- 11 -- 2011

CONTENTS

CONTENTS Page

Date

00 -- GENERAL GUIDELINES

Page

Date

21 -- GEAR TRANSMISSION

General instructions . . . . . 1--2

06--11

Safety regulations . . . . . . . 3--4--5

06--11

Tractor refuelling . . . . . . . . 6

06--11

10 -- ENGINE CHAPTER 1

CHAPTER 1 -- Mechanical transmission Specifications . . . . . . . . . . . 1--2

06--11

Tightening Torques . . . . . . 2--3

06--11

Tools . . . . . . . . . . . . . . . . . . 4

06--11

Sections . . . . . . . . . . . . . . . 5--6--7

06--11

Description and operation

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Troubleshooting . . . . . . . . . 8--9

06--11

General specifications . . . . 2--3

06--11

Engine removal--installation . . . . . . 4--5--6--7--8 --9--10

06--11

Removal--Installation -rear transmission -gearbox casing . . . . . . . . . . 10--11--12-13

06--11

Removal--Installation fuel tank . . . . . . . . . . . . . . . . . . . 11--12

06--11

Coolant radiator removal--installation . . . . . . 13--14--15

Disassembly--Assembly -transmission--gearbox casing . . . . . . . . . . . . . . . . . 17--18

06--11

Accelerator control cable adjustment . . . . . . . . . . . . . 16

Disassembly--Assembly -clutch casing . . . . . . . . . . . . 19--20--21

06--11

Sealing compound application diagram . . . . . . 22

06--11

Transmission oil cooler removal--installation . . . . . . 23

06--11

18 -- CLUTCH Specifications . . . . . . . . . . . 1

06--11

Tightening Torques . . . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . 2

06--11

Sections . . . . . . . . . . . . . . . 3

06--11

Troubleshooting . . . . . . . . . 4

06--11

Removal--Installation -clutch . . . . . . . . . . . . . . . . . . 5 Clutch Overhaul . . . . . . . . . 6--7--8--9 Checks and measurements -- clutch . . . 10--11

CHAPTER 3 -- Power Shuttle transmission Specifications . . . . . . . . . . . 1--2

06--11

Tightening Torques . . . . . . 3

06--11

Tools . . . . . . . . . . . . . . . . . . 4

06--11

Sections . . . . . . . . . . . . . . . 5--6--7

06--11

Description and operation . 8

06--11

Troubleshooting . . . . . . . . . 8

06--11

Disassembly--Assembly -clutch casing . . . . . . . . . . . . 9--10--11

06--11

Main clutch adjustments . . 12

06--11

Adjustments -- clutch disengagement levers . . . . 11

06--11

Adjustments -- clutch pedal 12

06--11

Sectional view of PTO clutch servo control . . . . . . 13

06--11

Description and operation of PTO servo control . . . . . 14--15

06--11

PTO servo control adjustment . . . . . . . . . . . . . 16 PTO engaged switch adjustment . . . . . . . . . . . . . 17

23 -- DRIVE LINES Specifications . . . . . . . . . . . 1

06--11

Tightening Torques . . . . . . 2

06--11

Sections . . . . . . . . . . . . . . . 3--4

06--11

Description and operation . 5

06--11

Troubleshooting . . . . . . . . . 6

06--11

Drive shafts and guard. Disassembly -- Assembly . 7

06--11

84419869A1 -- 11 -- 2011

CONTENTS

4 Page Removal--Installation -drive gear casing . . . . . . . . 8

06--11

25 -- FRONT AXLE MECHANICAL TRANSMISSION CHAPTER 1 -- Front mechanical transmission Specifications . . . . . . . . . . . 1--2

06--11

Tightening Torques . . . . . . 3--4

06--11

Tools . . . . . . . . . . . . . . . . . . 5

06--11

Sections . . . . . . . . . . . . . . . 6

06--11

Removal--Installation -front axle . . . . . . . . . . . . . . . 8--9--10

Page

Date

Adjustments -- differential lock engagement sleeve position . . . . . . . . . . . . . . . . 13

06--11

Adjustments -- bevel drive

06--11

14--15--16

Removal -- Installation side gear casing . . . . . . . . . 17--18--19-20

06--11

Disassembly--Assembly -drive wheel shaft . . . . . . . . 21--22

06--11

31 -- POWER TAKE--OFF CHAPTER 1 -- Mechanical power take--off

06--11

Front axle. Disassembly -- Assembly . 11--12--13-14--15--16-17--18

06--11

Replacing steering knuckle pins and bearings . . . . . . . 19

06--11

Adjustments -steering knuckle bearings . 20--21

06--11

Specifications . . . . . . . . . . . 1--2

06--11

Tightening Torques . . . . . . 3--4

06--11

Sections . . . . . . . . . . . . . . . 5--6

06--11

Description and operation . 7--8

06--11

Troubleshooting . . . . . . . . . 8

06--11

33 -- BRAKES Specifications . . . . . . . . . . . 1--2

11--11

Tightening Torques . . . . . . 2

06--11

Sections . . . . . . . . . . . . . . . 3

06--11

Overhaul -- front differential 29

06--11

Description and operation . 4

06--11

LIM--SLIP self--locking differential . . . . . . . . . . . . . . 30--31

06--11

Troubleshooting . . . . . . . . . 5--6

06--11

Checking leading wheel alignment . . . . . . . . . . . . . . 32

06--11

Removal--Installation -service brake . . . . . . . . . . . 7

06--11

Disassembly--Assembly -front epicyclic final drive . . 33--34

06--11

Removal--Installation -service brake pump . . . . . . 8--9

06--11

Adjustments -service brake pedals travel 10

06--11

Service brake circuit air bleeding . . . . . . . . . . . . . . . . 11--12

06--11

Adjustments -service brakes control . . . . 13

11--11

Parking locking on the transmission . . . . . . . . . . . . 14

11--11

Removal--installation of parking locking on the transmission . . . . . . . . . . . . 15

11--11

Adjustment of parking locking on the transmission 16

11--11

Adjustments -- bevel drive

22--23--24-25--26--27-28

27 -- REAR MECHANICAL TRANSMISSION Specifications . . . . . . . . . . . 1--2

06--11

Tightening Torques . . . . . . 3--4

06--11

Tools . . . . . . . . . . . . . . . . . . 5

06--11

Sections . . . . . . . . . . . . . . . 6--7

06--11

Description and operation . 8

06--11

Troubleshooting . . . . . . . . . 8

06--11

Disassembly--Assembly -transmission--gearbox casing . . . . . . . . . . . . . . . . . 9--10--11-12

84419869A1 -- 11 -- 2011

06--11

CONTENTS Page

Date

35 -- HYDRAULIC SYSTEMS

5 Page

Date

CHAPTER 5 -- Constant flow gear pump

CHAPTER 1 -- Rear mechanical hydraulic lift Specifications . . . . . . . . . . . 2

11--11

Tightening Torques . . . . . . 2--3

11--11

Tools . . . . . . . . . . . . . . . . . . 3

11--11

Sections . . . . . . . . . . . . . . . 4--5

11--11

Troubleshooting . . . . . . . . . 6

11--11

Specifications . . . . . . . . . . . 1

11--11

Description and operation . 2

11--11

Disassembly--Assembly -pump . . . . . . . . . . . . . . . . . . 2

11--11

Diagrams . . . . . . . . . . . . . . . 3

11--11

CHAPTER 8 -- Front Loader Specifications . . . . . . . . . . . 1

06--11

Sections . . . . . . . . . . . . . . . 2

06--11

Tightening Torques . . . . . . 3

06--11

Description and operation . 7--8--10--11 --12--13--14 --15

11--11

Troubleshooting . . . . . . . . . 4--5

06--11

Hydraulic diagram . . . . . . . 9

11--11

Parking the front loader . . . 6

06--11

Front loader arm connection bracket Removal--Installation . . . . . 7

06--11

Lift internal controls. 16--17--18-Disassembly -- Assembly . 19--20

11--11

Draft reading unit Disassembly -- Assembly . 20--21

11--11

Replacement of control struts (mod. MSL) . . . . . . . 8

06--11

Lift arms shaft. Disassembly -- Assembly . 22--23

11--11

Removal--Installation -lift distributor . . . . . . . . . . . . 24

Replacement of triangular articulation levers (mod. MSL) . . . . . . . . . . . . . 9

06--11

11--11

Bucket support device removal--installation . . . . . . 10

06--11

Adjusting the lift . . . . . . . . . 25--26--27-28

11--11

Position indicator disassembly--assembly . . . 11

06--11

Bushing replacement . . . . 12--13

06--11

Loader cylinder removal--installation . . . . . . 14

06--11

CHAPTER 2 -- Open centre system auxiliary distributors Specifications . . . . . . . . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . 2

06--11

Bucket control cylinder removal--installation . . . . . . 15

06--11

Tightening Torques . . . . . . 2

06--11

Replacement of pins . . . . . 16

06--11

Sections . . . . . . . . . . . . . . . 3--4

06--11

Description and operation .

5--6--7--8

Auxiliary distributors. Disassembly -- Assembly . 9--10--11

06--11

41 -- STEERING CHAPTER 1 -- Steering

06--11

CHAPTER 3 -- Trailer brakes auxiliary distributors Sections . . . . . . . . . . . . . . . 1

06--11

Description and operation . 1--2--3--4--5 --6--7

06--11

Troubleshooting . . . . . . . . . 8--9--10

06--11

Specifications . . . . . . . . . . . 2

06--11

Tightening Torques . . . . . . 2

06--11

Tools . . . . . . . . . . . . . . . . . . 3

06--11

Description and operation . 4--5--6

06--11

View of hydrostatic steering distributor components . . . 7

06--11

Troubleshooting . . . . . . . . . 8--9

06--11

84419869A1 -- 11 -- 2011

CONTENTS

6 Page Replacement -- hydrostatic steering wheel . . . . . . . . . . 10 Removal--Installation -hydrostatic steering distributor . . . . . . . . . . . . . . 11--12

Date 06--11

06--11

Disassembly--Assembly -hydrostatic distributor . . . . 13--14--15-16--17--18-19--20--21-22--23--24-25--26--27-28

06--11

Hydrostatic steering distributor bench testing . . 29--30

06--11

Pressure relief valve testing 31

06--11

Steering control cylinder. Removal -- Installation . . . . 32--33

06--11

Steering control cylinder. Disassembly--Assembly . . 34--35

06--11

Cab controls . .

Date

11--12--13

06--11

Testing operation and cooling . . . . . . . . . . . . . . . . . 14--15

06--11

Air conditioning system maintenance . . . . . . . . . . . . 16--17

06--11

Troubleshooting . . . . . . . . . 18--19--20-21

06--11

Refrigerant recovery--recycling and evacuation--charging stations . . . . . . . . . . . . . . . . 22--23

06--11

Dehydration, recharging and refrigeration check . . . 24--25--26-27--28--29-30

06--11

Checking for and eliminating any gas leaks . 31--32

06--11

Cab heating/air--conditioning system. Removal -- Installation . . . . 33--34

06--11

Cab electric fan unit. Disassembly -- Assembly .

44 -- AXLES AND WHEELS

Page

Specifications . . . . . . . . . . . 1--2

11--11

06--11

Front wheel track diagram

11--11

Sections . . . . . . . . . . . . . . . 3

11--11

Air--conditioning system condenser removal--installation . . . . . . . . . . . . . . . . . . 36

06--11

Tightening Torques . . . . . . 4--5--6

11--11

Tools . . . . . . . . . . . . . . . . . . 6--7

11--11

55 -- ELECTRICAL SYSTEM

Troubleshooting . . . . . . . . . 7

11--11

CHAPTER 1 -- Instruments

Disassembly--Assembly -wheel axle hub

8--9--10--11

11--11

Removal--Installation -front axle . . . . . . . . . . . . . . . 12--13--14-15--16

11--11

Stub axle hub overhaul . . . 17--18--19-20

11--11

Checking leading wheel alignment . . . . . . . . . . . . . . 21

11--11

50 -- CAB HVAC SYSTEM

Summary . . . . . . . . . . . . . . . 1

06--11

Digital analog instrument

06--11

Speedometer/tachometer . 3

06--11

LCD panel settings . . . . . . 3รท7

06--11

Coolant temperature . . . . . 7

06--11

Fuel level . . . . . . . . . . . . . . . 7

06--11

Indicator lights . . . . . . . . . . 8รท9

06--11

Transmitters, sensors and switches . . . . . . . . . . . . . . . 10รท20

06--11

Electronic control unit inputs/outputs (ADIC) . . . . 21รท23

06--11

Safety regulations . . . . . . . 2

06--11

Main Data . . . . . . . . . . . . . . 3

06--11

Tools . . . . . . . . . . . . . . . . . . 4

06--11

CHAPTER 2 -- Starting System

Operating principles . . . . . 5

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Technical data . . . . . . . . . . 2

06--11

Conditioning system components . . . . . . . . . . . . 6--7--8--9-10

84419869A1 -- 11 -- 2011

06--11

CONTENTS Page

7 Page

Date

How to use the wiring diagrams . . . . . . . . . . . . . . . 43÷47

06--11

Components in descriptive order . . . . . . . . . . . . . . . . . . 48÷52

06--11

List of tables for system without “standard and full optional” cab . . . . . . . . . 53--54

06--11

Components with code in ascending order . . . . . . . . . 55÷57

06--11

Tables . . . . . . . . . . . . . . . . . 58÷96

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

List of tables for system with “standard and full optional” cab 97--98

06--11

Technical data . . . . . . . . . . 2

06--11

Tightening Torques . . . . . . 2

06--11

Components with code in ascending order . . . . . . . . . 99÷103

06--11

Tools . . . . . . . . . . . . . . . . . . . 3

06--11

Tables . . . . . . . . . . . . . . . . . 104÷160

06--11

Description and operation . 3--4

06--11

CHAPTER 6 -- Wiring Harnesses and Connectors

System testing . . . . . . . . . . 5

06--11

Summary . . . . . . . . . . . . . . . 1

06--11

Belt Tension . . . . . . . . . . . . . 6

06--11

Alternator motor removal and installation . . . . . . . . . . 7--8

Components in descriptive order . . . . . . . . . . . . . . . . . . 2÷7

06--11

Components with code in ascending order . . . . . . . . . 8÷12

06--11

Harnesses . . . . . . . . . . . . . . 13÷20

06--11

Connectors . . . . . . . . . . . . . 21÷92

06--11

Tightening Torques . . . . . . 2

06--11

Description and operation . 3

06--11

Starter and recharging circuit . . . . . . . . . . . . . . . . . . 4--5

06--11

Troubleshooting . . . . . . . . . 6--7

06--11

Fuse and relay locations . . 7--8

06--11

System testing . . . . . . . . . . 8÷10 Starter motor removal--installation . . . . . . 11÷13

CHAPTER 3 -- Charging system

CHAPTER 4 -- Battery Summary . . . . . . . . . . . . . . . 1

06--11

Technical data . . . . . . . . . . 2

06--11

Description and operation . 2

06--11

90 -- PLATFORM, CAB, BODYWORK

Battery removal and 3 installation . . . . . . . . . . . . . .

06--11

CHAPTER 1 -- Cab

Battery testing and charging procedure . . . . . . 4÷14

06--11

CHAPTER 5 -- Electrical circuits Summary . . . . . . . . . . . . . . . 1

06--11

Maxi power fuses . . . . . . . . 2÷5

06--11

Power fuses . . . . . . . . . . . . 5÷34

06--11

Battery cut--out . . . . . . . . . . 34

06--11

Sockets . . . . . . . . . . . . . . . . 35--36

06--11

Grid heater . . . . . . . . . . . . . 37

06--11

Electronic modules . . . . . . 37--38

06--11

Main Connectors . . . . . . . . 38--39

06--11

Ground points identification 40÷42

06--11

Bonnet. Removal -- Installation . . . . 2

06--11

Cab assembly with platform. Removal -- Installation . . . . 3--4--5--6-7--8--9

06--11

Cab right--hand pillar guard removal -- installation . . . . . 10

06--11

Cab right--hand top guard removal -- installation . . . . . 11

06--11

Cab right--hand mudguard guard removal--installation 12

06--11

Cab left--hand top guard removal--installation . . . . . . 13

06--11

Windows. Replace . . . . . . . 14--15--16

06--11

84419869A1 -- 11 -- 2011

CONTENTS

8 Page

Date

CHAPTER 2 -- Platform Removal -- installation of slewing platform assembly 2--3--4--5--6 --7--8--9--10 --11--12--13 --14--15

11--11

Removal -- installation of safety canopy frame . . . . . 16

11--11

84419869A1 -- 11 -- 2011

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

SECTION 33 -- BRAKES Chapter 1 -- Braking system CONTENTS Section

Description

33 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Right or left--hand brake. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Braking system hydraulic pump. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Adjusting the brakes control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Parking locking on the transmission. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . 14

33 202 60 33 202 46

Page

MAIN DATA Type: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath disk, acting on differential drive shafts

parking brake (ISO version) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

the same disks as the service brakes

Parking brake (North American version) . . . . . . . . . . . . .

by means of gear on bevel pinion

Control: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydrostatic, with independent pedals (connected by means of a pin)

service brake . (North American version, with platform) . . .

mechanical, with independent pedals (connected by means of a pin)

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, by means of a hand lever

Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Number of discs for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . -(North American version, with platform) . . . . . . . . . . . . . . . . . .

N 653 no. no.

4 3

4.7 รท 4.8

Disk thickness: --

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(continued)

84419869A1 - 11 - 2011

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

MAIN DATA (overleaf)

Hydrostatic control Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with 2 master cylinders independently operated by brake pedals 17.6 (18 kg/cm2)

bar

Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 14

Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 15

TIGHTENING TORQUES PARTS TO BE TIGHTENED

Thread

Screws or nuts securing gear casing to transmission casing (C1) Brake control assembly retaining bolts (C2) . . . . . . . . . . . . . . . . . .

Tightening torque Nm

kgm

M12 x 1.25

117 รท 129

11.9 รท 13

60 รท 75

6.1 รท 7.6

84419869A1 - 11 - 2011

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

BRAKES CONTROL ADJUSTMENT (MECHANICALLY AND HYDRAULICALLY CONTROLLED MODELS)

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. Tractor complete but without fuel tank. 1. Take off the cover. 2. Insert a 7 mm shim (A) between the lever (1) and the support (2) (only for models with mechanically controlled brakes).

3. Screw on the nut (1) to a torque of 5 Nm (models with mechanically controlled brakes) or to a torque of 8 Nm (models with hydraulically controlled brakes). 4. Set the parking brake control lever in the brake disengaged position. 5. Connect the parking brake control cables to the relevant levers, eliminate any play in the cables and check that the cable connecting pin and its levers inserts and extracts freely. 6. Check that the parking brake control lever is in a horizontal position when the brake is disengaged.

7. Unscrew the nut (1) by two full turns and fit the cover in its seat. 8. Brake a few times to settle the system.

84419869A1 - 11 - 2011

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

PARKING LOCKING ON THE TRANSMISSION

18 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Fork. Fastening pin. Locknut. Safety peg. Retaining pin. Seal. Bush. Retaining bolt. Cam support. Return spring. Lever pivot pin (15). Control cam. Stop ring. Bearing.

84419869A1 - 11 - 2011

Diagram of parking locking components on the transmission 15. Internal control lever. 16. Pin. 17. Stop ring. 18. Washer. 19. Seal. 20. Washer. 21. Bearing. 22. Bush. 23. External control lever. 24. Fork. 25. Fastening pin. 26. Control tie--rod. 27. Locknut.

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

PARKING LOCKING ON THE TRANSMISSION Removal--Installation

2. Unscrew the retaining bolts (1) and remove the support (2) together with the control cam. 3. Refit the parking locking taking the following into consideration.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. --

Position the support complete with control cam and secure it.

Position the control tie--rod and secure it by means of the relevant pins.

84419869A1 - 11 - 2011

SECTION 33 -- BRAKING SYSTEM -- CHAPTER 1

ADJUSTMENT OF PARKING LOCKING ON THE TRANSMISSION

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Set the lever (1) in the locking off position. 2. Connect the control tie--rod (2) to the lever (1). 21 3. Turn the external control lever (3, fig. 21) until the control cam (2) comes into contact with the internal roller (1). 4. Adjust the length of the tie--rod (2, fig. 21) so that, with lever (1, fig. 21) pushed downwards, the tie--rod fixing pin can enter without any interference. 5. Engage and disengage parking locking a few times and check: -- that, with the lever (1, fig. 21) in the locking engaged position, the fork of the tie--rod (2, fig. 21) makes no interference with the lever (3, fig. 21); --

that, with the lever (1, fig. 21) from the locking disengaged position to the limit stop position, the hole in the lower fork of the tie--rod and the hole in the lever (3, fig. 21) travel more than 28 mm; that, with parking locking engaged, the fork of the tie--rod (1) and the external lever (2) make no interference with each other.

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Rear mechanical hydraulic lift CONTENTS Section

Description

Page

35 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

35 110 40

Lift internal controls. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

35 112 18

Draft sensing unit. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

35 110 10

Lift arms control shaft. Disassembly -- Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

35 112 10

Distributor assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 SPECIFICATIONS

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

With separate position and draft control, mixed position/draft control function, draft sensitivity adjustment and float function

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

Through two independent levers

Lift sensitivity adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drop rate adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Single--acting cylinder: -- Rated bore and stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm -- Displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3

90 x 117 750

Pressure regulating valve setting . . . . . . . . . . . . . . . . . . . . . . . bar

190 ÷ 195

Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . bar

220 ÷ 225

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm Category . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three--point linkage I and II By means of top link

Lift capacity at ball ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg Lift capacity with centre of gravity at 610 mm from the ball ends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg

2192

Maximum stroke of lower arms . . . . . . . . . . . . . . . . . . . . . . . . . mm With vertical tie--rods completely extended . . . . . . . . . . . . . . . mm

636 520

1662

TIGHTENING TORQUES Description

Thread

Torque Nm

Transmission gearbox/lift retaining bolts (C1) . . . . . . . . . . . . . . . . .

M10X1.25

67 ÷ 75

Transmission gearbox/lift retaining bolts (C1) . . . . . . . . . . . . . . . . .

M12X1.25

117 ÷ 129

Lift casing/distributor retaining bolts (C2) . . . . . . . . . . . . . . . . . . . .

M8x1.25

25 ÷ 30

Lift casing/hydraulic cylinder retaining bolts (C4) . . . . . . . . . . . . . .

M12X1.25

98 ÷ 127 (1)

Lift casing/hydraulic cylinder front retaining bolt (C4) . . . . . . . . . . .

68 ÷ 88 (1)

Three--point linkage support retaining bolts (C5) . . . . . . . . . . . . . .

M8x1.25

39 ÷ 49 (2)

(1) Apply Loctite 5699 -- (2) Apply Loctite 243.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TIGHTENING TORQUES

C5 C4 C1

1 List of specific tools required for the various operations described in this section. X 9970873

Lift arms shaft seal drift.

X 9970874

Arm lift adjustment wrench.

X 9970877

Fitting for pressure check kit.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

2 Hydraulic lift longitudinal section. 1. 2. 3.

Distributor. Lift body. Lift rocker shaft.

84419869A1 - 11 - 2011

4. 5. 6.

Top link support (draft sensing unit). Draft sensing rod. Internal control linkages (for position/draft control).

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

3 Hydraulic lift distributor longitudinal view. A. Oil coming from the pump. 1. Distributor pin.

5. Safety valve. 16. Pilot valve oil drain line.

2. 3. 4.

17. Oil drain line to the tank. 27. Pilot valve.

Control piston. Non--return valve. Exhaust valve.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC LIFT TROUBLESHOOTING Problems

Possible causes

Solutions

The lift has difficulty in supporting the load, there are rhythmic oscillations with the engine running, the load lowers with the engine switched off.

1. 2.

There are rhythmic oscillations with the arms lifted up to the rear limit switch device and the engine running; with the engine switched off the load fails to lower

Incorrect adjustment of the lever of Adjust the position control lever. the position control that, at the greatest lift height, causes the automatic operation of the rear limit switch device.

Working in draft control mode, the implement drops too far or fails to remain in the furrow.

Incorrect setting of the distributor Adjust the distributor sensitivity. sensitivity.

3. 4.

Worn piston ring. Exhaust valve not calibrated.

Replace seal. Adjust the sensitivity in the distributor or replace the valve. Oil seepage from the safety valve. Remove the distributor and adjust or Oil seepage from the check valve. repair the valve. Remove the distributor and adjust or repair the valve.

The draft control does not work, the lift 1. raises and lowers only with the position control lever.

Incorrect adjustment of the draft Adjust the draft control lever. control lever.

The position control does not work, the lift raises and lowers only with the draft control lever.

1. 2.

Incorrect adjustment of the position Adjust the position control lever. control lever. Overhaul the lift. Internal linkages damaged.

The lift operates in jerks.

1. 2.

Low level of oil in the tank. Pump inlet filter clogged.

Top up oil. Clean or replace filter.

Air in the pump suction line.

Check the suction pipe, fittings and seal.

Lift not working.

Differential valve blocked or dirty.

Remove the distributor and free the regulator piston.

The lift starts to rise but stops when it detects the load and the pressure relief valve has not tripped.

The size (L, fig. 39) of the tie--rod Adjust the draft control lever. (T) is not the prescribed one.

The lift fails to lower completely as far as the limit stop.

Incorrect adjustment of the position Adjust the position control lever. control lever (1).

The lift fails to lower.

Exhaust valve blocked.

Remove the distributor and free or clean the exhaust valve.

The lifting capacity does not correspond to the specifications.

Deterioration in the distributor seal rings. Relief and safety valves off setting. Pump faulty. Excessive seepage of oil from the distributor.

Remove the distributor and replace the outside seal rings. Check the calibration of the valves. Replace pump. Have the distributor overhauled.

2. 3. 4.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC SYSTEM

DESCRIPTION AND OPERATION

CAUTION

The system is controlled by the Draft Control lever (2) and the Position Control lever (1). Position control operation Position Control provides accurate control of implements, such as sprayers, rotary harrows, etc., that operate above the ground. Once set, Position Control will maintain the selected implement height. IMPORTANT: Always set the system to Position Control at any time when not actually operating in Draft Control, such as when attaching or transporting equipment or when no equipment is attached. Move the draft control lever (2) fully forward in the quadrant. Set the required implement height/depth using the Position Control lever (1). Pull the lever back to raise the implement, push forward to lower. Implement height/depth is relative to the position of the lever in the quadrant. An adjustable stop enables moving the lever back to the required work position.

Draft control operation Move the position control lever (1) fully forward. Lower the tool into the work position using the draft control lever (2). Push the lever forward to increase the draft loading. Pull rearwards to reduce the draft loading. Forward movement of the draft control lever will increase implement depth and rearward movement will reduce the depth. Once set, the tractor hydraulic system will automatically adjust the implement depth to maintain an even pull on the tractor and so reduce wheel slip to a minimum.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

3 Hydraulic diagram 1. 2. 3.

Lift hydraulic distributor. Hydraulic Power lift. Safety valve.

4. 5. 6.

Lift cylinder. Hydraulic pump. Pressure relief valve.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

4 ARM LIFT PHASE

In this phase the distributor sends the pressurised oil to the lifting cylinder (23) with the arms lifting as a result. The position of the distributor pin (1) enables connecting the compartment (26) of the pilot valve (27) with the oil coming from the pump (A) through the ring pipe (19) and the holes (20, 21 and 30) allowing the valve to close. The oil under pressure feeds the compartment (22) and the compartment (15), with the same pressure, through the pipe (29) of the control piston (2) which, under the action of the associated return spring, closes the discharge holes (17).

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The oil under pressure via: the ring pipe (19), restriction (6), distributor pin (1) and the pipe (21), opens the check valve (3) and through the ring pipe (18) feeds the lifting cylinder (23). The control piston (2) regulates the flow of oil to the cylinder (23) as the compartments (15) and (22) are subject to a difference in pressure created by the restrictions (6) and (31) (between the distributor pin (1) and its seat) depending on its motion caused by the internal linkages of the lift. The excess flow is switched to the discharge holes (17).

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

5 NEUTRAL PHASE

In this phase the distributor keeps the oil under pressure inside the lifting cylinder while the oil coming from the pump (A) flows freely out through the holes (17). The position of the distributor pin (1) connects the compartment (26) of the pilot valve (27) with the discharge pipe (16), meanwhile the valve (27) opens the hole (28) that enables discharging the oil from the compartment (15) through the pipe (29) of the control piston (2). The oil coming from the pump (A) fills the compartment (22) that moves the control piston (2)

opening the discharge holes (17) allowing the oil to flow out of the tank. The oil contained in the lifting cylinder (23) is maintained under pressure by the check valve (3), discharge valve (4) and safety valve (5) connected together by the pipe (18) thus maintaining the load applied to the arms. The safety valve (5) protects the cylinder from any possible overpressure due to the load swinging when driving on roads.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

6 ARM LOWER PHASE

In this phase the distributor discharges both the oil coming from the pump (A) and from the lifting cylinder (23), as a result the lift arms lower. The position of the distributor pin (1) connects the compartment (26) of the pilot valve (27) with the discharge pipe (16), meanwhile the valve (27) opens the hole (28) that enables discharging the oil from the compartment (15) through the pipe (29) of the control piston (2).

84419869A1 - 11 - 2011

The oil coming from the pump (A) fills the compartment (22) that moves the control piston (2) opening the discharge holes (17) allowing the oil to flow out of the tank. At the same time, the oil coming from the lifting cylinder (23) enters the ring pipe (18), crosses: the holes (32), lowering control (8) and hole (24) then crossing through the discharge valve (4) it flows to the tank via the hole (25), this allows the lift arms to lower.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 INTERNAL CONTROL LINKAGES A) Position control operation B) Draft control operation C) Combined position and draft control operation Position control operation Refer to figure 7. Positioning the draft control lever (2) against the limit stop completely detaches the roller (11) that runs in the flywheel (7) of the draft control cam (12). In this position, the linkages of the draft control do not interfere with those of the position control. The arms are lifted by moving the position control lever (1) upwards and the control linkages will operate in the following manner: The articulation (4), integral with the shaft (3), turns clockwise and slides the roller (5) on the position control cam (6), as a result causing clockwise rotation of the flywheel (7). The flywheel transmits the rotary thrust in an anticlockwise direction, by

means of a friction strut (8), to the relay rod (9), that as a result moves the distributor shaft (21) into the delivery position, making the lift arms raise. During the arm raising stroke, the articulation (13) with the pin (10) turns anticlockwise and, operating on the lever (14), it makes the position control cam (6) turn clockwise. When the roller (5) comes into contact with the sloping face of the cam (6), it enables anticlockwise rotation of the flywheel (7) that, operating on the friction strut (8), rotates the lever (9) clockwise, loaded by the spring of the distributor control shaft (21), actuating the distributor in the neutral position (phase) and as a result blocking the movement of the lift arms. During the lowering phase, the movement of the above described levers takes place in the opposite direction. The position of the arms, during the phases of lifting and lowering, corresponds to that of the control lever (1).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Draft control operation Refer to figure 8. By positioning the position control lever against the limit stop, the articulation (4) (fig 7.) moves into the position of maximum anticlockwise rotation. In this position, the roller (5) is fully lowered with respect to the sloping face of the position control cam (6), enabling anticlockwise rotation of the flywheel (7) and clockwise rotation of the relay rod (9), loaded by the spring of the shaft (21), that in its turn moves into the discharge position. In this position, the linkages of the position control do not interfere with those of the draft control. Refer to figure 8. Positioning the draft control lever (2) against the limit stop, makes the draft control shaft (16) rotate clockwise. The articulation (15), integral with the shaft (16), reaches the limit of clockwise rotation and, by means of the tie--rod (17), moves the roller (11), that in its turn operates on the draft control cam (12). This makes the flywheel (7) rotate clockwise that, operating on the friction strut (8), actuates the relay rod (9) anticlockwise, taking the distributor shaft (21) into the delivery position, consequently raising the arm. The arms stop only when the piston comes into contact with the pin of the limit stop (22). This limit stop, by means of the tie--rod (23), makes the lever (9) rotate clockwise, as a result compressing the spring of the friction strut (8) and thus freeing the shaft (21), that can therefore move into the neutral position, pushed by the respective spring. Moving the draft control lever towards the limit stop, the control linkage operates in the following manner:

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Combined operation of position and draft control Refer to figure 8. To use the lift in these conditions it is necessary to observe the following instructions: â&#x20AC;˘ Move the position control lever upwards with respect to the limit stop until the greatest working depth is obtained. â&#x20AC;˘ Set the minimum desired working depth by means of the draft control lever, raising it from the zero position so that the roller (11), that actuates the draft control cam (12), moves the control shaft of the distributor (21) into the lifting position, making the lift arms raise further. Thanks to the position previously determined by means of the position control lever (1), the flywheel

(7), the roller (4) and the position control cam (6), the control shaft of the distributor (21) cannot pass onto the lowering position S and as a result the arms cannot sink into the ground even if the force of traction acting on the top link (20) tends to decrease, negatively pressing on the tie--rod (18). This condition does not prevent the lift from working in draft control when, with more compact ground, the force of traction acting on the top link (20) tends to increase, positively pressing on the tie--rod (18). As a result, the combined position and draft control operation limits the height variations of the implement with respect to the ground, as occurs when working in draft control, and at the same time it enables keeping the implement at the greatest set working depth.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

OP. 35 110 40 LIFT INTERNAL CONTROLS D.A. (With the lift removed)

ATTENTION Handle all components with the greatest care. Do not insert hands or fingers between one part and another. Wear suitable protection clothing, including goggles, gloves and footwear.

Proceed as follows. 1. Unscrew the fixing screws and remove the external lift control lever assembly (1).

2. Unscrew the Allen screws (1).

10 3. Remove the cylinder (1) from the hydraulic lift casing.

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

NOTE: Extract the seal (1) from the cylinder head.

12 4. Extract the piston (1) from the cylinder by pressing with a suitable aluminium bar from the front.

1 13 5. Take off the catches and remove the lever (1).

14 6. Remove the articulation (1).

1 15 84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

7. Remove the catch (1) from the pin of the compensator.

16 8. Unscrew the compensator pin until that the face of the pin comes out of the compensator.

17 9. Remove the articulations as shown in the figure.

18 10. Remove the articulation (1).

1 19 84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

11. Unscrew the clamping screws (1) and remove the position control cam (2) and the bracket (3).

2 20

12. Remove the pin (1).

21 13. Remove the cam (1).

22 14. Take off the catch (1) and remove the articulation (2).

23 84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

15. Unscrew the clamping screw (1) and remove the lever (2) together with the articulation (3).

Assembly

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

16. Go ahead and assemble the internal controls of the hydraulic lift proceeding in the opposite direction to disassembly.

Op. 35 112 18 DRAFT SENSING UNIT Disassembly -- Assembly

25 2. Take off the catch (1) and remove the parallel piece (2).

2 1 26

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

3. Unscrew the bolts (1) and the Allen screw.

27 4. Remove the pin as shown in the figure. 5. Remove the sensing unit from the lift casing.

28 6. Unscrew the Allen screws (1). 7. Remove the roller (2), springs (3), cover (4) and flange (5) from the draft sensing unit. 8. To fit the draft sensing unit, proceed as follows.

5 4 3

ATTENTION

Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

1 29 ----

Reassembly follows the removal procedure in reverse, from step 7 back to step 1. Tighten all fasteners to the correct torques as detailed on page 3. The top surface of the spring roller: i) must be L = 1 รท 1.2 mm above the top surface of the flange ii) if at a lower distance, add shims, if at a higher distance, remove shims. Refer to the respective page for the correct adjustments. 30 84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Op. 35 110 10 LIFT ARMS DRIVE SHAFT Disassembly -- Assembly

ATTENTION Handle all components with the greatest care. Do not insert hands or fingers between one part and another. Wear suitable protection clothing, including goggles, gloves and footwear.

Proceed as follows. 1. Remove the circlip (1) from the lift arms drive shaft.

1 31 IMPORTANT: Before removing them, use a punch (1) to mark the assembly positions of both lift arms and shafts to facilitate assembly in the original position. 2. Detach the lift arm from the shaft.

32 3. Repeat the operation on the other lift arm. 4. Remove the blocking sensor (1), blocking articulation and the shaft.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

5. Press the shaft from the left--hand side towards the right by lightly tapping with a mallet on an aluminium or copper bar. 6. To fit the arms drive shaft, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

34 -----

1 35

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Op. 35 112 10 DISTRIBUTOR UNIT Removal -- Installation

36 IMPORTANT: Before installing them, check that the O--rings of the distributor (1) are not damaged, replacing them if necessary.

1 37

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 ADJUSTMENTS If completely dismantling the lift, it is necessary to make the following adjustments. A) Adjust the position and draft control levers. B) Adjust the reaction spring C) Adjust the internal push rod A) Adjust the position control levers Refer to figure 38. This adjustment sets the position of greatest lift of the lift arms. Completely lower the arms and apply a light weight to them, sufficient to produce a pressure of 50 ↵ 60 bar in the cylinder. Unscrew the fixing screws (6) so as to free the position control lever (1) from the shaft (5). With the draft control lever (2) completely lowered against the limit stop, lift the position control lever (1) against the limit stop.

Keeping the levers (1) and (2) stationary and with a 13 mm socket wrench, slowly rotate the position control shaft (5) clockwise so as to lift the arms up to the position of greatest height, determined by the internal hydraulic limit stop. Since, during the position control work, it is necessary to avoid activating the hydraulic limit stop, it is necessary to have a safety margin of tolerance (L) of 10 ÷ 15 mm. To this end, slowly rotate the shaft (5) clockwise as far as to lower the arms to the margin of tolerance with respect to the position of the lift limit stop. Now, keep the shaft (5) stationary and, with the lever (1) against the stop, secure the lever to the shaft, fully tightening the screw (6). To check the adjustment, completely lift the arms moving the position control lever (1) against the limit stop; completely lifting the draft control lever (2) there must be an additional upward movement of the lift arms. This movement must come within the distance of 15 ÷ 20 mm.

MMR0231A

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

B) Adjusting the draft control lever Refer to figure 39. The draft control lever adjustment is used to set it correctly into phase with the working stroke (positive and negative) of the bracket of the top link so as to be able to use the reaction spring with the greatest effectiveness. The adjustment should be made without any implements connected or loads applied to the top link (20) (and that is to say in the neutral position). Fully lower the two control levers (1) and (2). With the engine running at idle speed, slowly lift the draft control lever (2).

The adjustment of the draft control lever (2) is correct when, moving it forwards by the distance (L1) = 15 รท 16 mm, the lift arms raise completely. If the lever (2) fails to raise the arms completely before reaching the prescribed distance (L1), shorten the distance (L) of the tie--rod (T). If the lever (2) fails to raise the arms completely after passing the prescribed distance (L1), lengthen the distance (L) of the tie--rod (T). NOTE: The position of the lever (1) determines only that of the arms and does not affect the adjustment of the draft control lever (2).

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

C) Adjusting the reaction spring Refer to figure 41. For the lift to function correctly, the bracket of the top link, when not working, must have no end float in the positive (+) and negative (--) directions of operation. If the parts have been fitted correctly, the spring carrier (2) should rest against the lift casing (1) and the cover of the spring carrier (4) against the flange (3). In this condition, the spring (M) is pre--loaded (compressed) by approximately 1.0 Ăˇ 1.2 mm.

40 Before fitting the whole reaction unit on the lift casing, pre--assemble the spring (M) so as to obtain a measurement of (L) â&#x2030;&#x2026; 8.4 mm. On completing assembly of the reaction unit, make the definitive adjustment. Keeping the screw (V) stationary with an 8 mm wrench, adjust the self--locking nut (D), tightening or loosening it so as to eliminate the end float completely.

84419869A1 - 11 - 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

D) Adjusting the internal push rod Refer to figure 42. If it is necessary to dismantle the lift and replace the regulator (R), it is advised to measure the distance “X” (≅10.5 mm) so as to be able subsequently to reassemble the push rod in the same position. In addition, check that the measurement (A) of the spring is 52.00 ÷ 52.3 mm. The distance (B) between the push rod and the surface of the distributor is to be measured after making all the adjustments (draft sensitivity of the distributor, position control lever and draft control lever).

With the lift arms completely lowered and with no loads or implements connected to the three--point linkage (neutral position), completely lower the two position and draft control levers against the related limit stops. In this position, press the push rod and, using an appropriate gauge, check that the distance (B) is 112.0 ÷ 112.5 mm. NOTE: If the distance “X” has changed, it will necessarily be necessary to repeat the adjustment of the position and draft control levers.

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SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 5 -- Non--stop flow gear pump CONTENTS Operation

Description

Page

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic pump diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

BOSCH 19 + 11 OR 19 + 14 HYDRAULIC PUMP SPECIFICATIONS (POWER SHUTTLE VARIANT) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from rear transmission casing.

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

on right--hand side of engine

Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BOSCH 19 + 11 or 19 + 14 (power shuttle variant) BOSCH driven by engine shaft clockwise 1 : 1.08

Manufacturer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum speed of rotation (with engine at maximum power 2300) . . . rpm Pump (A) corresponding rated output . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Pump (A) rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Pump (B) corresponding rated output . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Pump (B) rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Pump (B, power shuttle) corresponding rated output . . . . . . dm3/min (I/min) Pump (B, power shuttle) rated output at 1000 rpm . . . . . . . . dm3/min (I/min)

2484 47.20 19 27.32 11 34.77 14

Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..................................................................

full--flow, with replaceable paper cartridge

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

on pump intake

84419869A1 -- 11 -- 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5 DESCRIPTION AND OPERATION

The hydraulic pump (A) serves the hydraulic lift, the trailer brake valve and the auxiliary distributors. The hydraulic pump (B) serves the power steering and the various services: differential lock, power take--off, four--wheel drive engagement and Power Shuttle gearbox. The different types of pump shown above are of the gear type with spur gears and function with non--stop flow according to the engine rpm. They are fitted on a support on the right--hand side of the engine and are driven by a timing gear.

OP. 35 104 30 LIFT OIL PUMP D.A.

(With the pump removed) Disassembly

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

The oil is taken from the rear transmission casing, passing through a filter. Proceed as follows: 1. Take out the retaining bolts (11, fig. 1). 2. Remove the circlip (22, fig. 1). 3. Mark the parts (3, 5, 6, 7, 8, 10, 12, 14, 15, 16, 17 and 18) and dismantle the hydraulic pumps (A) and (B) into their component parts. Once the parts are removed, proceed as follows.

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 4. Clean all constituent parts thoroughly. 5. Replace the seals (1, 4, 9, 13, 18 and 22). 6. Lubricate the parts with the same oil as the system. 7. Always work in very clean conditions, to prevent contamination from foreign matter which could damage the pumps. 8. Assemble the hydraulic pumps by carrying out the disassembly operations in reverse order and making reference to fig. 1.

84419869A1 -- 11 -- 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

1 Components of the BOSCH 19 + 11 or 19 + 14 pumps

A. Lift hydraulic pump. B. Services hydraulic pump. 1. Seal. 2. Bush. 3. Cover. 4. Seals. 5. Gear support. 6. Drive and driven gears. 7. Gear support. 8. Pump body. 9. Seals. 10. Cover.

11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Screw. Cover. Seals. Pump body. Gear support. Drive and driven gears. Gear support. Seals. Cover. Bush. Circlip.

Seal.

84419869A1 -- 11 -- 2011

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 5

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

SECTION 44 -- AXLES AND WHEELS Chapter 1 -- Axles and wheels CONTENTS Section

Description

Page

44 000

Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

44 101 22

Front axle hub. Disassembly--Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

44 101 30

Front axle. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

44 101 46

Stub axle. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

44 511 46

Checking the alignment of the leading wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

inverted U--section, U section, telescopic and oscillating at centre

Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2°, corresponding to approx. 15 mm for 16” rims

Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0÷5

Diameter of stub axle pin (7, page 3) at bushings (6) . . . . . . . . . .

37.961÷38.000

Internal diameter of fitted bushings (6) . . . . . . . . . . . . . . . . . . . . . .

”

38.050÷38.140 (*)

Clearance between stub axle pin and bushings . . . . . . . . . . . . . . .

”

0.050÷0.179

Diameter of axle articulation pin (1, page 3) . . . . . . . . . . . . . . . . .

37.961÷38.000

Internal diameter of fitted bushings (2) . . . . . . . . . . . . . . . . . . . . . .

”

38.050÷38.140 (*)

Clearance between stub axle pin and relative bushings . . . . . . . .

”

0.050÷0.179

Stub axle articulation

Axle articulation

(*) Value to be obtained without refacing.

(continued)

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

SPECIFICATIONS (overleaf)

Wheel tracks (mm) Models

T4.55 T4 55 T4.65 T4 75 T4.75

Tyres

6.5--16

1429

1529

1629

1729

1829

1929

7.50--16

1449

1549

1649

1749

1849

1949

25/10.5LLX15

1495

1595

1695

1795

1895

1995

2WD front wheel track diagram

A B C D

27460

F E mm 1

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

SECTIONS

8 9

25990

4 2 Sections of stub axle, articulation pin and front axle

1. 2. 3. 4. 5. 6. 7. 8. 9.

Axle articulation pin. Axle articulation bushings. Steering transverse tie--rod. Stub axle pin control lever. Axle support. Bushings. Stub axle pin. Support ring grub screw (13). End cap.

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

Bronze thrust ring. Seal. Wheel hub. Tapered roller bearing for wheel. Cover for bearing greasing and adjustment. Steel thrust ring. Grub screw for cap (11) and thrust washer (12). Control cylinder fulcrum pin (18). Control cylinder installation position.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

TIGHTENING TORQUES

C1 -- 49 Nm

C2 -- 115 Nm C6 -- 186 รท 206 Nm

C5 -- 186 รท 206 Nm

C3 -- (*)

C5 -- 49 รท 68.7 Nm

C4 -- 186 รท 257.7 Nm

25991

3 Torque settings -- front axle wheel hub side C1 C2 C3 C4 C5

Axle pivot pin retaining bolt. Disk to hub retaining bolt. Bearings adjuster nut. Axle end retaining nut. Cover for wheel hub bearing greasing.

84419869A1 - 11 - 2011

C6 Stub axle pin control lever retaining bolt nut. C7 Nut securing cylinder to fulcrum pin. (*) See operations 12 and 13, page 13

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

C8 -- 102 รท 123.5 Nm

C9 -- 125 รท 154.5 Nm

C10 -- 29.4 รท 46.4 Nm 25992

4 Torque settings front axle steering tie--rod side C8 Stub head locknut for steering transverse tie--rod. C9 Locknut for steering transverse tie--rod.

C10 Nut securing power steering cylinder pipes.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED

Thread Nm

kgm

Front axle Axle articulation pin retaining bolt (C1, page 4) .

M 10x1.25

Nut (C2) securing leading wheel to hub . . . . . . . . . . . . . . . . . . . . . . .

M 18x1.5

115

11.7

Nut (C3) for bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 20x1.5

(*)

Nut (C4) for pin securing end of axle . . . . . . . . . . . . . . . . . . . . . . . . .

M 20x1.5

186÷257.7

19÷26.3

Cover (C5) for wheel hub bearing greasing . . . . . . . . . . . . . . . . . . . .

49÷68.7

5÷7

Nut (C6) for stub axles left and right--hand levers retaining bolt . . .

M 14x1.5

186÷206

19÷21

Nut (C7) securing cylinder to fulcrum pin . . . . . . . . . . . . . . . . . . . . . .

M 18x1.5

186÷206

19÷21

Stub head locknut (C8, page 5) for steering transverse tie--rod . . .

M 16 x 1.5

102÷123.5

10.4÷12.6

Locknut (C9) for steering transverse tie--rod . . . . . . . . . . . . . . . . . . .

M 20x1

Nut (C10) securing power steering cylinder pipes . . . . . . . . . . . . . . .

125÷154.5 12.7÷ 15.7 29.4÷46.4

3÷4.75

(*) See operations 12 and 13, page 13

84419869A1 - 11 - 2011

List of specific tools required for the various operations described in this section. 380000237

Wheel lifting hook.

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

27855

5 Tool to be made for extracting the front axle articulation pin (to be used with an extracting tool -- Stamp No. 50145 on the tool -- Measurement in mm) Construct in C40 material -- Pin 3 x 20 mm.

TROUBLESHOOTING Problems

Possible causes

Abnormal tyre wear.

1. Incorrect pressure.

tyre

Poor tractor stability.

1. Incorrect pressure.

tyre

Solutions

inflation Inflate the tyres to the correct pressure, referring to the recommended pressures in the Use and Maintenance handbook, and the pressures indicated by the tyre manufacturers. 2. Incorrect front wheel toe--in. Correct the toe--in. inflation Inflate the tyres to the correct pressure, following the instructions given above.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

Op. 44 101 22 FRONT AXLE HUB Disassembly--Assembly DISASSEMBLY

ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 1. Lock the rear wheels using suitable chocks. 2. Using suitable lifting equipment, raise the front of the vehicle. 6 3. Place a suitable stand under the engine sump and insert a wooden block between the engine sump and the stand.

7 4.

Remove the front wheel.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

5. Remove the wheel hub bearing nut cover.

9 6. Remove the split pin (1) and wheel hub bearing adjuster nut (2).

10 7. Remove the washer (1) and wheel hub (2).

11 8. Remove the inner wheel bearing (1). Replace the seal (2) as necessary.

12 84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

9. Remove the bearing carriers from the wheel hub.

ASSEMBLY 10. Pack the new bearings with AMBRA GR9. 11. Install the new bearing carriers and seal into the wheel hub. 12. Fill the wheel hub with AMBRA GR9 grease.

14 13. Install the wheel hub (1) complete with bearings onto the stub axle. Install the washer (2).

15 14. Using a torque wrench, tighten the adjuster nut (1) to a torque of 98 Nm (10 kgm), whilst rotating the wheel hub to correctly seat the bearings. 15. Loosen the adjuster nut (1), then tighten again to a torque of 24 to 29 Nm (2.5 to 3 kgm) whilst continuing to rotate the wheel hub. 16. In stall the split pin (2).

16 84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

17. Install the wheel hub bearing nut cover.

17 18. Install the front wheel. Tighten the retaining bolts to the specified torque.

18 19. Using suitable lifting equipment, raise the front of the vehicle. 20. Remove the stand from under the vehicle. 21. Lower the vehicle. 22. Connect the battery.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

Op. 44 101 30 FRONT AXLE Removal--Installation

REMOVAL 1. Lock the rear wheels using suitable chocks. 2. Using suitable lifting equipment, raise the front of the vehicle.

20 3. Place a suitable stand under the engine sump and insert a wooden block between the engine sump and the stand.

21 4. Remove the front wheels.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

5. Disconnect the steering cylinder hoses.

23 6. Using suitable lifting equipment, support the front axle.

24 7. Remove the axle articulation pin retaining bolt.

25 8. Using adaptor 50145 (1) (see page 7) and a suitable slide hammer (2), remove the front axle articulation pin (3).

26 84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

9. Remove the front axle. 10. Note: Recover the front axle spacers and shims.

INSTALLATION

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 11. Position the front axle under the vehicle making sure that the front axle shims and spacers are in position.

28 12. Install the front axle articulation pin.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

13. Install the front axle articulation pin retaining bolt.

30 14. Remove the lifting equipment from the front axle.

31 15. Connect the steering cylinder hoses.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

16. Install the front wheels. Tighten the retaining bolts to the specified torque.

33 17. Using suitable lifting equipment, raise the front of the vehicle and remove the stand from under the vehicle.

34 18. Remove the stand from under the vehicle. 19. Lower the vehicle. 20. Connect the battery.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

Op. 44 101 46 STUB AXLE Overhaul

ATTENTION Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. Proceed as follows for each wheel, remembering that the stub axles can be removed without removing the axle from the tractor. 1. Lock the front wheels using chocks. 25993

2. Lift the front of the tractor.

36 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.

25994

37 4. Remove the front wheel retaining bolts (1).

24767

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

5. Position a hydraulic jack under the stub axle and unscrew the bolt (1) securing the control lever (2) to the stub axle pin.

24782

39 6. Withdraw the control lever (1) from the stub axle pin (2).

24783

40 7. Lower the hydraulic jack and remove the stub axle (1).

24784

1 41

8. Unscrew the bolts securing the axle end (1).

42 84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

9. Remove the axle end (1).

24786

43 10. Clamp the end of the axle in a vice and, using an extractor tool, extract the stub axle pin articulation bushings (1).

1 24787

44 11. To refit the stub axle, follow the disassembly procedure in reverse order, using a striker to fit the new bushings on the axle ends.

24788

45 12. Fit the axle end (1).

24786

46 84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

13. Refit the cap (9, fig. 2), at the base of the stub axle, then the shim adjuster rings (1) inserting them on the stop grub screws (8 and 14, as shown in fig. 2).

24789

47 14. Fit the stub axle on the axle end. 15. Position the control lever (1) on the stub axle pin (2) then tighten the retaining bolt.

24783

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

Op. 44 511 80 CHECKING THE ALIGNMENT OF THE LEADING WHEELS

ATTENTION A

Handle all parts with care. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

A+X

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

B+0÷5 mm

Check the alignment of the leading wheels, bearing in mind that for driving in a straight line, the wheels must be at an angle of 2° to the ground, corresponding to a difference of approximately 15 mm, for 16” rims, between the top and bottom edges of the rim (fig. a).

B 8821

When driving in a straight line, the wheels must also be parallel to longitudinal axis of the tractor, or have a maximum of 5 mm toe--in at the front, as measured between the edges of the rims. To check the correct toe--in, proceed as follows:

1. Inflate the front tyres to a pressure of 2.5 bar (kg/cm2). 2. Position the steering at half--lock with a straight--edge along the longitudinal axis of the tractor. 3. Check that the wheels are parallel to the longitudinal axis of the tractor. 4. On the horizontal plane passing between the centres of the wheels, measure the distance (B) between the front inside edges of the rims (see fig. b). 5. On the horizontal plane passing between the centres of the wheels, measure the distance between the rear inside edges of the rims, checking that the distance is equal to (B) or exceeds it by up to a maximum of 5 mm. 6. If necessary, correct the toe--in by adjusting the end of the transverse steering tie--rod.

84419869A1 - 11 - 2011

SECTION 44 -- AXLES AND WHEELS -- CHAPTER 1

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

SECTION 90 -- PLATFORM Chapter 2 -- Platform CONTENTS

Operation

Description

Page

90 110 36

Platform assembly. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

90 150 10

Safety canopy frame. Removal -- Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

OP. 90 110 36 PLATFORM ASSEMBLY Removal--Installation

ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

REMOVAL 1. Remove the safety frame roof. 2. Lock the rear wheels using suitable chocks. 3. Using suitable lifting equipment, or with the aid of suitable tools, support the bonnet 4. Disconnect the bonnet wiring harness (1). 5. Disconnect the bonnet strut (2). 6. Using suitable lifting equipment, or with the aid of suitable tools, remove the bonnet retaining bolts (3) and remove the bonnet. 1 7. Remove the engine side panels.

84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

8. Remove the bonnet support frame front retaining bolts.

3 9. Remove the bonnet support frame.

10. Remove the exhaust.

5 11. Disconnect the accelerator cable (1) and remove from the fuel injection pump (2).

6 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

12. Disconnect the steering hoses.

13. Disconnect the hydraulic oil pump outlet pipe.

8 14. Disconnect the connectors.

engine

harness

electrical

9 15. Connect the brake fluid reservoir electrical connectors.

10 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

16. Disconnect the steering hose.

11 17. Disconnect the range lever cables (1). Detach the range lever cables and bracket (2) from the transmission and position to one side.

12 18. Disconnect the gear change lever cables (1) Detach the gear change lever cables and bracket (2) from the transmission and position to one side.

13 19. Disconnect the power take--off brake cable (1) Detach the power take--off brake cable and bracket (2) from the transmission and position to one side.

14 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

20. Remove the split pin (1), and pin (2) and detach the power take--off shift cable from the transmission.

15 21. Disconnect the clutch cable (1) and detach the cable (2) from the transmission. 22. Disconnect the handbrake cable.

16 23. Disconnect the left--hand brake pipe.

17 24. Disconnect the right--hand brake pipe.

18 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

25. Disconnect the inline electrical connector.

19 26. Disconnect connector.

the

trailer

auxiliary

electrical

20 27. Disconnect earth strap.

21 28. Using suitable lifting equipment, support the front left--hand side of the platform assembly.

Carry out the same operation on the right--hand side.

22 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

29. Using suitable lifting equipment, support the rear of the platform assembly.

23 30. Remove the platform assembly rear right--hand retaining bolt.

Carry out the same operation on the left--hand side.

24 31. Remove the platform assembly front left--hand retaining bolt.

Carry out the same operation on the right--hand side.

25 32. Remove the platform assembly. Note: Carefully raise the user platform, making sure that all interconnecting parts are disconnected.

26 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

Installation (Op. 90 110 36 )

ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear. 33. Using suitable lifting equipment, locate the platform assembly onto the vehicle.

27 34. Install the platform assembly front left--hand retaining bolt.

Carry out the same operation on the right--hand side.

84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

35. Install the platform assembly rear right--hand retaining bolt.

Carry out the same operation on the left--hand side.

29 36. Remove the lifting equipment, from the rear of the platform assembly.

30 37. Remove the lifting equipment, from the front left--hand side of the platform assembly.

Carry out the same operation on the right--hand side.

31 38. Connect the ground wire.

32 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

39. Connect the trailer auxiliary electrical connector.

33 40. Connect the inline electrical connector.

34 41. Connect the right--hand brake pipe.

35 42. Connect the left--hand brake pipe.

36 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

43. Attach the clutch cable to the transmission (1) and connect the clutch cable (2). 44. Connect the handbrake cable.

37 45. Attach the power take off shift cable to the transmission and install the pin (1) and install the split pin (2).

38 46. Attach the power take off brake cable and bracket to the transmission (1), and connect the power take off brake cable (2).

39 47. Attach the gear change lever cables and bracket to the transmission (1) and connect the gear change lever cables (2).

40 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

48. Attach the range lever cables and bracket to the transmission (1) and connect the range lever cables (2).

41 49. Connect the steering hose.

42 50. Connect the brake fluid reservoir electrical connectors.

43 51. Connect the connectors.

engine

harness

electrical

44 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

52. Connect the hydraulic oil pump outlet pipe.

45 53. Connect the steering hoses.

46 54. Install the accelerator cable clip (1) and connect the accelerator control cable (2) to the injection pump.

47 55. Install the exhaust manifold.

48 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

56. Install the bonnet support frame.

49 57. Install the bonnet support frame front retaining bolts.

50 58. Install the engine side panels.

51 59. Using suitable lifting equipment, or with the aid of another technician, locate the bonnet into position and install the retaining bolts (1). 60. Connect the bonnet strut (2). 61. Connect the bonnet wiring harness (3). 62. Connect the battery. 63. Bleed the brakes. 64. Install the safety frame roof.

52 84419869A1 - 11 - 2011

SECTION 90 -- PLATFORM, CAB, BODYWORK -- CHAPTER 2

OP. 90 114 10 SAFETY FRAME ROOF Removal -- Installation

ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.

Removal Proceed as follows.

1. Remove the six retaining bolts (1) and the roof (2) from the frame (3).

Installation

27810

ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.

Proceed as follows.

2. Fit the roof (2) on the frame (3), and tighten the six retaining bolts (1).

84419869A1 - 11 - 2011