T4040 − T4050 TRACTORS SERVICE MANUAL SECTIONS GENERAL GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 00 ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TRANSMISSIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 DRIVE LINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 FRONT MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 REAR MECHANICAL TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 POWER TAKE−OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 AXLE AND WHEELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 PLATFORM, CAB, BODYWORK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
T E C H N I C A L
S U P P O R T
INTRODUCTION −
This manual is divided into sections identified by two−figure numbers and each section has independent page numbering. For easy reference, these sections have the same numbers and names as the Repairs Rate Book sections.
−
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.
−
Pages updated in the future will be identified by the same document number followed by an additional digit: first edition standard manual 87744428A − 1st update 87744428A1 − 2nd update 87744484A2 − etc. The update pages can replace or supplement the pages of the standard manual; the information necessary for the procedure for adding or replacing 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 87744428B, this indicates that the manual is composed of the standard version 87744484A completed with all the updates: 1st update 87744484A1 − 2nd update 87744428A2 − 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 Manufacturer’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 reproduced
PRINTED IN FRANCE
CNH GLOBAL N.V. Print No. 87744428A − 11 − 2007
CONTENTS
3
CONTENTS Page
00 − GENERAL GUIDELINES General instructions . . . . .
1−2
11−03
Safety regulations . . . . . . .
3−4−5
11−03
Consumables . . . . . . . . . . .
6
11−03
Summary . . . . . . . . . . . . . .
1
11−07
General specifications
2−3−4
11−07
4
11−07
5
11−07
5
11−07
Connecting rod data . . . . .
6
11−07
Piston data . .
6−7
11−07
Timing gear data . . . . . . . .
7
11−07
Cylinder head data . . . . . .
8−9
11−07
Torque Specifications . . . .
10−11
11−07
Tools . . . . . . . . . . . . . . . . . .
12
11−07
Engine diagrams . . . . . . . .
13
11−07
Lubrication diagrams . . . .
14
11−07
Engine cooling system diagram . . . . . . . . . . . . . . . . . . 15
11−07
10 − ENGINE
Fuel system data . . . . . . . . Engine block data . . . . . . . Crankshaft data . . . . . . . . .
Additional counterweight 16 diagrams . . . . . Exhaust gas recirculation system (EGR) . . . . . . . . . . 17
Engine removal−installa- 22−23−24− tion . . . . . . . . . . 25−26−27− 28−29−30
Engine disassembly−assembly . . . . . . . . . . . . . . . . . 31−32−33− 34−35−36− 37−38−39− 40−41−42− 43−44−45− 46−47−48− 49−50−51− 52−53−54− 55−56−57− 58−59−60− 61−62−63− 64 Checks and measurements − cylinder block and 65−66−67 liners . . . . . . . .
Date
11−07 11−07
Checks and measurements − crankshaft, bearings and flywheel . . . . . . . . 68−69
11−07
Checks and measurements − connecting rods . 70−71
11−07
Checks and measurements − pistons . . . . . . . . 72−73−74− 75
11−07
Checks and measurements − camshaft, tappets and valves . . . . . . . . . . . . . 76−77−78− 79
11−07
11−07
Checks and measurements − cylinder head . . . 80
11−07
11−07
Checks and measurements − lubrication system 81
11−07
11−07
Checks and measurements − cooling system . . 82
11−07
Fault diagnosis . . . . . . . . . . 18−19−20− 21
Page
Date
Removal−Installation − crankshaft front seal . . . . . 11−07
83−84
11−07
Replacing crankshaft rear seal 85−86−87
11−07
Valve clearance adjustment . . . . . . . . . . . . . . . . . . . 88−89
11−07
Removal−Installation − in- 90−91−92 jectors . . . . . . . Removal − Installation − Bosch injection pump . . . . 93−94−95
11−07
11−07
87744428A − 11 − 2007
CONTENTS
4
Page Bosch injection pump − timing . . . . . . . . . . 96−97−98
Date 11−07
Bosch injection pump − air bleeding . . . . . 98
11−07
Removal−Installation − coolant pump . . . . . . . . . . . 99−100
11−07
Removal−Installation − thermostat valve . . . . . . . . 101−102
11−07
Removal−Installation radiator . . . . . .
− 103−104− 105−106
Coolant pump and generator drive belt . 107−108
11−07 11−07
18 − CLUTCH
Removal−Installation − Rear transmission − gearbox casing . . . . . . . . . . . . .
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . .
Page
Date
17−18−19− 20−21−22− 23
11−03
24−25−26− 27−28−29− 30−31
11−03
Gearbox driving and driven shafts clearance adjustment. . . . . . . . . . . . . . . . . . . 32
11−03
Sealing compound application diagram . . . . . . . . . . . . 33
11−03
Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Tightening torques . . . . . .
2
11−03
Tools . . . . . . . . . . . . . . . . . .
2
11−03
Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Cross−sectional views . . . 3−4
11−03
Tightening torques . . . . . .
3
11−03
Fault diagnosis . . . . . . . . . .
11−03
Tools . . . . . . . . . . . . . . . . . .
4−5−6−7−8
11−03
Removal−Installation − clutch . . . . . . . . . . . . . . . . . . Clutch Overhaul . . . . . . . . .
5 6−7−8−9− 10
11−03
11−12−13− 14−15
11−03
Checks and measurements − clutch . . . . . . . . . . 16−17
11−03
Adjustments − clutch disengagement levers . . . . . . . . 17−18
11−03
Adjustments − clutch pedal 19
11−03
PTO clutch lever adjustment . . . . . . . . . . . . . . . . . . . 20
11−03
21 − TRANSMISSIONS CHAPTER 1 − Transmissions and range gear (12x12) and (16x16) Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Tightening torques . . . . . .
2−3
11−03
Tools . . . . . . . . . . . . . . . . . .
4−5−6−7
11−03
Cross−sectional views . . . 8−9−10−11 −12−13−14
11−03
Description and operation
15
11−03
Fault diagnosis . . . . . . . . . .
15−16
11−03
87744428A − 11 − 2007
CHAPTER 2 − Power Shuttle transmission (16x16)
Cross−sectional views . . . 9−10−11− 12−13
11−03
Clutch control pressure test 12
11−03
Description and operation
14
11−03
Fault diagnosis . . . . . . . . . .
14
11−03
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . .
15−16
11−03
Disassembly−Reassembly − Power Shuttle control valve . . . . . . . . . . . . . . . . . . 17−18−19
11−03
Disassembly−Assembly − accumulator . . . . . . . . . . . .
11−03
20
Gearbox control valve solenoid valve. Removal − Installation . . . . . . . . . . . . . 21−22 Disassembly−Assembly − clutch casing . . . . . . . . . . .
23−24−25− 26−27
11−03
11−03
CONTENTS
Page
Date Disassembly−Assembly − epicyclic final drive . . . . . .
23 − DRIVE LINES Data . . . . . . . . . . . . . . . . . . .
1
11−03
Tightening torques . . . . . .
2
11−03
Tools . . . . . . . . . . . . . . . . . .
3−4
11−03
Cross−sectional views . . . 5−6−7
11−03
Description and operation
8−9
11−03
Fault diagnosis . . . . . . . . . .
9
11−03
Removal−Installation − drive gear casing . . . . . . . .
11−12
11−03
Disassembly−Assembly − drive gear casing . . . . . . . .
13−14−15− 16
5
Page
Date
34−35−36
11−03
Replacement − wheel hub seal . . . . . . . . . . . . . . . . . . . 37
11−03
Replacing steering knuckle pins and bearings . . . . . . . 38
11−03
LIM−SLIP self−locking differential . . . . . . . . . . . . . . . . 39−40
11−03
Checking leading wheels alignment . . . . . . . . . . . . . . 41
11−03
27 − REAR AXLE MECHANICAL TRANSMISSION 11−03
Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
25 − FRONT AXLE MECHANICAL TRANSMISSION
Tightening torques . . . . . .
3−4
11−03
Tools . . . . . . . . . . . . . . . . . .
5−6−7−8
11−03
CHAPTER 1 − Front axle mechanical transmission
Cross−sectional views . . . 9−10
11−03
Description and operation
11
11−03
11
11−03
12−13−14− 15−16−17
11−03
Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Fault diagnosis . . . . . . . . . .
Tightening torques . . . . . .
3−4
11−03
Tools . . . . . . . . . . . . . . . . . .
5−6
11−03
Disassembly−Assembly − transmission−gearbox casing . . . . . . . . . . . . . . . . .
Cross−sectional views . . . 7−8−9
11−03
Description and operation
11−03
Removal−Installation − front axle . . . . . . . . . . . . . . .
9 10−11−12− 13
11−03
Front axle. Disassembly − Assembly . . . . . . . . . . . . . . 14−15−16− 17−18−19− 20
11−03
Adjustments − steering knuckle bearings . . . . . . . . 21−22
11−03
Adjustments − bevel drive
23−24−25− 26−27−28− 29
11−03
Sealing compound application diagram . . . . . . . . . . . . 29
11−03
Overhaul − front differential 30
11−03
Disassembly − assembly epicyclic final drive with brake . . . . . . . . . . . . . . . . . . 31−32
11−03
Replacement − wheel hub seal . . . . . . . . . . . . . . . . . . . 33
11−03
Adjustment − differential lock engagement sleeve position . . . . . . . . . . . . . . . . 18 Adjustments − bevel drive
19−20−21− 22−23
11−03 11−03
Adjustment − differential lock control pedal travel . . 24
11−03
Removal−Installation − side gear casing . . . . . . . .
25−26
11−03
Disassembly−Assembly − drive wheel shaft . . . . . . . .
27−28
11−03
Disassembly−Assembly − epicyclic final drive . . . . . .
29
11−03
87744428A − 11 − 2007
CONTENTS
6
Page
Date
Fault diagnosis . . . . . . . . . .
16−17
11−03
18−19−20− 21
11−03
22−23−24− 25−26−27− 28−29−30− 31
11−03
Lift cylinder and arms shaft. Disassembly − Assembly . 32−33−34− 35
11−03
Disassembly−Assembly − lift control valve . . . . . . . . . 36−37−38− 39
11−03
Lift pressure relief valve . . 40
11−03
Lift internal controls. Disassembly − Assembly .
31 − POWER TAKE−OFF CHAPTER 1 − Mechanical power take−off Data . . . . . . . . . . . . . . . . . . .
1−2−3
11−03
Tools . . . . . . . . . . . . . . . . . .
4
11−03
Tightening torques . . . . . .
5
11−03
Cross−sectional views . . . 6
11−03
Description and operation
7−8−9
11−03
Fault diagnosis . . . . . . . . . .
9
11−03
Disassembly − Assembly − power take−off . . . . . . . . . . 10−11−12− 13
11−03
CHAPTER 2 − Open centre system auxiliary control valves
33 − BRAKES Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Tightening torques . . . . . .
2
11−03
Cross−sectional views . . . 3−4−5
11−03
Tools . . . . . . . . . . . . . . . . . .
5−6
11−03
Description and operation
6
11−03
Fault diagnosis . . . . . . . . . .
7−8
11−03
Removal−Installation − service brake . . . . . . . . . . . . . . 9−10
Adjustments − service brake pedals travel . . . . . . 16
11−03
Service brake circuit air bleeding . . . . . . . . . . . . . . . 16−17−18
11−03
Removal−Installation − parking brake . . . . . . . . . . .
11−03
Adjustments − parking handbrake travel . . . . . . . . 20
11−03
CHAPTER 1 − Rear mechanical hydraulic lift Data . . . . . . . . . . . . . . . . . . .
1−2−3
11−03
Tightening torques . . . . . .
3−4
11−03
Tools . . . . . . . . . . . . . . . . . .
5−6
11−03
87744428A − 11 − 2007
12−13−14− 15
11−03
Tools . . . . . . . . . . . . . . . . . .
2
11−03
Tightening torques . . . . . .
2
11−03
Cross−sectional views . . . 3−4
11−03
Description and operation
5−6−7−8
11−03
Auxiliary control valves. Disassembly − Assembly . 9−10−11
11−03
Cross−sectional views . . . 1 Description and Operation
35 − HYDRAULIC SYSTEMS
Cross−sectional views . . . 7−8−9−10− 11
2
CHAPTER 3 − Trailer brakes auxiliary control valves 11−03
19−20
Data . . . . . . . . . . . . . . . . . . .
11−03
Removal−Installation − service brake pump . . . . . . . . 11−12−13− 14−15
Description and operation
Adjusting the lift . . . . . . . . .
11−03 11−03
11−03
1−2−3−4−5 −6−7
11−03
Fault diagnosis . . . . . . . . . .
8−9−10
11−03
Removal−Installation − trailer brake valve . . . . . . .
11
11−03
CHAPTER 4 − Non−stop flow gear pump Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Description and Operation
2
11−03
Diagrams . . . . . . . . . . . . . .
3
11−03
Disassembly−Assembly − lift oil pump . . . . . . . . . . . . .
4
11−03
CONTENTS
Page
Date
7
Page
Date
41 − STEERING
Fault diagnosis . . . . . . . . . .
7
11−03
CHAPTER 1 − Steering
Disassembly−Assembly − wheel axle hub . . . . . . . . . .
8−9−10
11−03
Removal−Installation − front axle . . . . . . . . . . . . . . .
11−12−13
11−03
Data . . . . . . . . . . . . . . . . . . .
2
11−03
Tightening torques . . . . . .
2
11−03
Tools . . . . . . . . . . . . . . . . . .
2
11−03
Description and Operation
3−4−5
11−03
View of hydrostatic steering control valve components 6
11−03
Fault diagnosis . . . . . . . . . .
11−03
7−8
Replacement − hydrostatic steering wheel . . . . . . . . . . 9 Removal−Installation − hydrostatic steering control valve . . . . . . . . . . . . . . . . . . 10−11−12− 13−14
11−03
Checking leading wheels alignment . . . . . . . . . . . . . . 18
11−03
55 − ELECTRICAL SYSTEM CHAPTER 1 − Instruments
11−03
11−03
Disassembly−Assembly − hydrostatic control valve . . 15−16−17− 18−19−20− 21−22−23− 24−25−26− 27−28−29− 30
11−03
Hydrostatic steering control valve bench testing . . . . . . 31−32
11−03
Pressure relief valve testing 33
11−03
Steering control cylinder. Removal − Installation . . . 34−35
11−03
Steering control cylinder. Disassembly − Assembly . 36−37
11−03
Analogue instrumentation
2−3−4−5−6
11−03
Digital Instrument Cluster .
7−8−9−10− 11−12
11−03
Transmitters, sensors and switches . . . . . . . . . . . . . . . 13−14−15− 16−17
11−03
Service . . . . . . . . . . . . . . . .
11−03
18−19−20
CHAPTER 2 − Starting system
CHAPTER 2 − Non−stop flow gear pump Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Diagrams . . . . . . . . . . . . . .
3−4
11−03
Description and Operation
4
11−03
Disassembly−Assembly − hydrostatic steering oil pump . . . . . . . . . . . . . . . . . . 5
Stub axle hub overhaul . . . 14−15−16− 17
11−03
44 − AXLES AND WHEELS Data . . . . . . . . . . . . . . . . . . .
1−2
11−03
Front wheel track diagram
2
11−03
Cross−sectional views . . . 3
11−03
Tightening torque . . . . . . .
4−5−6
11−03
Tools . . . . . . . . . . . . . . . . . .
6−7
11−03
Technical data . . . . . . . . . .
1
11−03
Description and Operation
2
11−03
Fault diagnosis . . . . . . . . . .
3
11−03
System testing . . . . . . . . . .
4−5−6
11−03
Removal−Installation starter motor . . . . . . . . . . . .
6
11−03
Overhaul − starter motor .
7−8
11−03
Starter motor testing . . . . .
9−10
11−03
CHAPTER 3 − Charging system Technical data . . . . . . . . . .
1
11−03
Tightening torques . . . . . .
1
11−03
Description and Operation
2−3
11−03
System testing . . . . . . . . . .
4−5−6−7−8 −9
11−03
Removal−Installation and Overhaul − alternator . . . . 9−10−11− 12−13−14− 15−16
11−03
87744428A − 11 − 2007
CONTENTS
8
Page
Page
Date
CHAPTER 4 − Battery
Date
90 − PLATFORM, CAB, BODYWORK
Technical data . . . . . . . . . .
1
11−03
CHAPTER 1 − Bodywork
Description and Operation
1
11−03
Bonnet. Removal − Installation . . . . . . . . . . . . . . . . . . . . 2
11−03
Protective grill. Removal − Installation . . . . . . . . . . . . . 3
11−03
Dashboard. Removal − Installation . . . . . . . . . . . . .
11−03
Removal−Installation − battery . . . . . . . . . . . . . . . . . . . . 2
11−03
Battery maintenance . . . . .
3
11−03
Battery charging . . . . . . . .
4−5−6
11−03
Battery troubleshooting . . 6
11−03
CHAPTER 5 − Electrical circuits (w) Contents . . . . . . . . . . . . . . .
1
11−03
CHAPTER 6 − Connectors Index . . . . . . . . . . . . . . . . . .
87744428A − 11 − 2007
1
11−03
4−5−6−7
Removal−Installation fixed roll bar . . . . . . . . . . . . . . . . . 8−9
11−03
Removal−Installation right or left−hand mudguard . . . 10−11
11−03
Replacement − rear guard
11−03
12−13−14
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1
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; − coat 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, LOCTITE 5205, SUPERBOND 559 MASCHERPA or BETABLOCK A272M GURIT ESSEX. Before applying the sealing compound, prepare the surfaces as follows: − remove any incrustations using a wire brush; − thoroughly de−grease the surfaces using one of the following cleaning agents: trichlorethylene, petrol or a water and soda solution.
BEARINGS When installing bearings it is advised to: − heat the bearings to 176 to 194 °C (80 to 90 °C) before fitting on the shafts; − allow the bearings to cool before installing them from the outside.
87744428A − 11 − 2007
2
SECTION 00 − GENERAL GUIDELINES − 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 original 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 in the “Microfiches” or the “Spare Parts Catalogue”, used for order processing.
TOOLS The tools that NEW HOLLAND propose and illustrate in this manual are: − specifically researched and designed for use with NEW HOLLAND vehicles; − essential for reliable repair operations; − accurately built and rigorously tested so as to offer efficient and long−lasting operation. By using these tools, repair personnel will benefit from: − operating in optimal technical conditions; − obtaining the best results; − saving 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 vehicle 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 vehicle 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.
87744428A − 11 − 2007
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1
3
SAFETY REGULATIONS 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: CAUTION − Warnings concerning unsuitable repair operations that may jeopardise the safety of Service personnel. DANGER − Specific warnings concerning potential hazards for operator safety or for other persons directly or indirectly involved.
ACCIDENT PREVENTION 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 REGULATIONS
1 −
Do not carry out repair operations with someone sitting in the driver’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 driver’s seat.
−
Do not carry out operations on the vehicle with the engine running, unless specifically indicated.
−
Stop the engine and check that the hydraulic circuits are pressure−free 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. Any parts that are to be raised must be locked in position.
−
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 position until filling operations are completed in order to avoid possible sparks caused by the accumulation of static electricity.
GENERAL GUIDELINES − −
Carefully follow specified repair and maintenance procedures. Do not wear rings, wristwatches, jewellery, unbuttoned or loose articles of clothing such as: ties, torn clothing, scarves, open jackets or shirts with open zips that may remain entangled in moving parts. It is advised to wear approved safety clothing, e.g.: non−slip footwear, gloves, safety goggles, helmets, etc.
87744428A − 11 − 2007
4 −
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1 Only use specified towing points for towing the tractor. 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 tractor 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.
−
When carrying out checks with the engine running, request the assistance of an operator in the driver’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 operator’s seat. Also check that there are no persons within the tractor or implement range of action.
−
Always use suitable hoisting or lifting devices when raising or moving heavy parts.
−
Take extra care if bystanders are present.
−
Never pour gasoline 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.
−
Do not keep into your pockets any object which might fall unobserved into the tractor’s inner compartments.
−
Wear safety goggles with side guards when cleaning parts with compressed air.
−
−
Limit the air pressure to a maximum of 30.45 psi (2.1 bar), according to local regulations.
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 carefully. Do not put your hands or fingers between moving parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
−
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 protective equipment: helmets, goggles and special footwear.
87744428A − 11 − 2007
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1 START UP
HYDRAULIC SYSTEMS
−
−
−
Never run the engine in confined spaces that are not equipped with adequate ventilation for exhaust gas extraction. Never bring your head, body, arms, legs, feet, hands, 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.
−
−
−
−
−
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 “jumpers” (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.
A liquid leaking from a tiny hole may be almost invisible but, at the same time, be powerful enough to penetrate the skin; therefore, NEVER USE HANDS TO CHECK FOR LEAKS. Use a piece of cardboard or wood for this purpose. 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 −
− −
−
ELECTRICAL SYSTEMS
5
−
− −
Check 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 tractor 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 INSTALLATION −
−
−
Lift and handle all heavy parts using suitable hoisting equipment. Ensure that parts are supported by appropriate slings and hooks. Use lifting eyes provided to this purpose. Extra care should be taken if persons are present near the load to be lifted. Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Avoid twisting chains or metal cables. Always wear safety gloves when handling cables or chains.
87744428A − 11 − 2007
6
SECTION 00 − GENERAL GUIDELINES − CHAPTER 1 CONSUMABLES
COMPONENT TO BE FILLED OR TOPPED UP
QUANTITY US gal. (litres)
Cooling system: without cab . . . . . . . . . . . . . .
14,0
Windscreen wash reservoir
2,0
Fuel tank: − standard model − with double tank . . . . . .
65 82
Engine oil sump: without filter: . . . . . . . . . . . . .
8,9
with filter: . . . . . . . . . . . . . . . .
9,5
Brake control circuit . . . . . .
0,7
With front brakes . . . . . . . . .
1,0
RECOMMENDED NEW HOLLAND PRODUCTS
NEW HOLLAND SPECIFICATI ONS
INTERNATIONAL SPECIFICATIONS
Water & liquid AMBRA AGRIFLU 50% + 50%
NH 900 A
−
Water & liquid
−
−
Decanted, filtered diesel fuel
−
−
Oil AMBRA MASTERGOLD HSP
NH 324H (SAE 10W−30) NH 330H (SAE 15W−40)
Oil AMBRA BRAKE LHM
NH 610 A
AMBRA MULTI G oil
NH 410 B
API GL4 ISO 32/46 SAE 10W−30
NH 710 A
NLGI 2
API CI−4/CH$ ACEA E7/E5
ISO 7308
Front axle: axle casing . . . . . . . . . . . . . . final drives without brakes (each) . . . . . . . . . . . . . . . . . . final drives with brakes (each) . . . . . . . . . . . . . . . . . .
1.18 (4.5) 0.26 (1.0) 0.39 (1.5)
Rear transmission (bevel drive, final drives and brakes), gearbox, hydraulic lift, PTO and hydraulic steering:
11.09 (42)
Grease fittings . . . . . . . . . . .
−
87744428A − 11 − 2007
AMBRA GR9 grease
SECTION 10 − ENGINE − CHAPTER 1
1
SECTION 10 − ENGINE
Chapter 1 − Engine CONTENT Section
Description
Page
10 000
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Schematic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
10 001 10
Engine Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10 001 54
Engine Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
10 102 70
Crankshaft front seal − Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10 102 74
Crankshaft rear seal − Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10 106 12
Valve/rocker arm clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10 218 30
Engine injectors Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10 246 14
Bosch injection pump Removal−Installation, timing and air bleeding . . . . . . . . . . . . . . . . . 93
10 402 10
Coolant pump Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10 402 30
Thermostatic valve Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
10 406 10
Radiator Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
10 414 10
Coolant pump and generator drive belts Adjusting tension . . . . . . . . . . . . . . . . . . . . . . . . 107
87744428A − 11 − 2007
2
SECTION 10 − ENGINE − CHAPTER 1
GENERAL SPECIFICATIONS Engine, technical type: −
Model T4040 type F4CE9484N*J601 (BOSCH pump) . . . .
−
Model T4050 − type F4CE9484M*J601 (BOSCH pump) . .
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
diesel, 4−stroke
Fuel injection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Direct
Number of cylinders in line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
Piston diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104 mm
Piston stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
132 mm
Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4485 cm3
Compression ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.5:1
Maximum Power Output: −
Model T4040 − type F4CE9484N*J601 . . . . . . . . . . . . . . . . .
63 kW (86 Hp)
−
Model T4050 − type F4CE0454C*D600/*D603 . . . . . . . . . .
71 kW (97 Hp)
Maximum power speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2300 rpm
−
Maximum torque: Model T4040 − type F4CE9484N*J601 .
370 Nm
−
Maximum torque: Model T4050 − type F4CE9484M*J601
418 Nm
Maximum torque speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1300 rpm
Number of main bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
Sump pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
structural, cast iron
Lube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
forced, with lobe pump
Pump drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
from crankshaft
Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . .
1:1
Oil filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mesh screen on oil pick−up and filter cartridge in delivery line
Normal oil pressure with motor warmed−up at slow idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 bar
at fast idling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.9 bar (continued)
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
3 (overleaf)
GENERAL SPECIFICATIONS Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
coolant circulation
Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 lines of vertical pipes with copper fins
Fan, attached to the pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
intake, in plastic with 11 blades
Coolant pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
centrifugal vane−type
Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . . Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature ranges corresponding to each section: − Initial blue section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − Middle green section (normal working conditions) . . . . . . . . . − Final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1:1.977 coloured scale divided into three sections
Temperature Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via thermostat valve
−
initial opening . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
40° ÷ 60 °C 60° ÷ 110 °C 110° ÷ 120 °C 81 ± 2 °C
Valve 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10° ± 30’
−
end: after B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10° ± 30’
Exhaust: −
start: before B.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
64°
−
end: after T.D.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26°
Clearance between valves and rocker arms with engine cold: −
intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 ± 0.05 mm
−
exhaust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 ± 0.05 mm
Power supply Air filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
dual cartridge dry air filter, with clogged filter indicator with centrifugal pre−filter and automatic dust ejector
Fuel pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with double diaphragm
Fuel filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . through wire filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump Minimum fuel flow rate with pump shaft rotating at 1800 rpm .
127.6 l/h
Cam operated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
via engine timing (continued)
87744428A − 11 − 2007
4
SECTION 10 − ENGINE − CHAPTER 1 (overleaf)
GENERAL SPECIFICATIONS 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 HX25 rotating distributor with speed governor and advance variator incorporated
BOSCH pump: −
Model T4040 − type F4CE9484N*J601 . . . . . . . . . . . . . . . . .
VE 4/12 F1150−2856534
−
Model T4050− type F4CE9484M*J601 . . . . . . . . . . . . . . . . .
VE 4/12 F1150−2856537
Direction of rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Injection order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
anticlockwise 1−3−4−2 (for all models)
SPECIFICATIONS
BOSCH−type injectors: F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . .
2856255
Number of nozzle holes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Nozzle hole diameter mm: F4CE9484N*J601/F4CE9484M*J601 . . . . . . . . . . . . . . . . .
0.237
Calibration pressure bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
260 ÷ 274
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
ENGINE BLOCK DATA
5
mm
Engine sump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
cast−iron monobloc with cylinder liners, crankshaft, camshaft and tappets
Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
104.000 ÷ 104.024
Oversized cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .
104.400 ÷ 104.424
Main journal half bearing seat diameter
external
no. 1−5
87.982 ÷ 88.008
internal
no. 2−3−4
87.977 ÷ 88.013
Camshaft bushing seat diameter: − front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
59.222 ÷ 59.248
Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .
16.000 ÷ 16.030
CRANKSHAFT AND BEARINGS DATA
mm
Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
balanced with integral counterweights
Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
82.99 ÷ 83.01
Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.250 − 0.500
Main journal half bearing thickness . . . . . . . . . . . . . . . . . . . . . . . . .
2.456 ÷ 2.464
Main bearing shell undersizes on internal diameter . . . . . . . . . . . .
0.250 − 0.500
Clearance between bearings and main journal
no. 1−5
0.022 ÷ 0.053
no. 2−3−4
0.019 ÷ 0.055
Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
68.987 ÷ 69.013
Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.250 − 0.500
Standard connecting rod half bearing thickness . . . . . . . . . . . . . . .
1.955 ÷ 1.968
Big−end bearing shell undersizes on internal diameter . . . . . . . . .
0.250 − 0.500
Bearing to crankpin clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.019 ÷ 0.058
Standard crankshaft thrust washer width . . . . . . . . . . . . . . . . . . . .
37.280 ÷ 37.380
Width of main bearing for thrust . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32.180 ÷ 32.280
Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . .
37.475 ÷ 37.550
Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.095 ÷ 0.270
87744428A − 11 − 2007
6
SECTION 10 − ENGINE − CHAPTER 1
CONNECTING ROD DATA
mm
Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
printed in steel, oblique−cut type
Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .
40.987 ÷ 41.013
Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .
41.279 ÷ 41.553
Interference between small end bushing and seat . . . . . . . . . . . . .
0.266 ÷ 0.566
Internal diameter of small end bushing (after press−fitting) . . . . .
38.019 ÷ 38.033
Diameter of seat for bearing shells on connecting rod . . . . . . . . .
72.987 ÷ 73.013
Connecting rod−crankpin end float . . . . . . . . . . . . . . . . . . . . . . . . . .
0.100 ÷ 0.330
PISTON DATA Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm light alloy with three compression rings, including two seal rings and one scraper ring
Standard piston diameter, measured at 61 mm from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . . . . . . . . . . .
103.714 ÷ 103.732
Piston clearance in cylinder liner . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.268 ÷ 0.310
Spare piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0,400
Piston protrusion at T.D.C. from cylinder block face . . . . . . . . . . .
0.280 ÷ 0.520
Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
37.994 ÷ 38.000
Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . . .
38.010 ÷ 38.016
Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.010 ÷ 0.022
Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . . .
0.019 ÷ 0.039
Piston ring seat depth: − 1st ring (measured on a diameter of 99 mm) . . . . . . . . . . . . . . .
2.705 ÷ 2.735
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.440 ÷ 2.460
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.030 ÷ 4.050
Piston ring thickness: − 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.560 ÷ 2.605
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.350 ÷ 2.380
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.970 ÷ 3.990 (continued)
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
7 (overleaf)
PISTON DATA
mm
Piston ring groove clearance (measured vertically): − 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.100 ÷ 0.175
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.060 ÷ 0.110
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.040 ÷ 0.080
Assembly clearance between piston ring ends in cylinder sleeves: − 1st ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.30 ÷ 0.40
− 2nd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.60 ÷ 0.80
− 3rd ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.30 ÷ 0.55
Spare piston ring oversizing . . . . . . . . . . . . . . . . .
.....
......
VALVE TIMING GEAR DATA
0.400
mm
Internal diameter of camshaft support bushings (press−fitted and finished in seats): − front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
54.083 ÷ 54.147
Diameter of camshaft journals: − front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
− mid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
− rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
53.995 ÷ 54.045
Clearance between camshaft journals and bushings . . . . . . . . . .
0.038 ÷ 0.152
Camshaft end float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.230 ± 0.130
Crankshaft to camshaft teeth clearance . . . . . . . . . . . . . . . . . . . . .
0.076 ÷ 0.280
TAPPET DATA
mm
Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16.000 ÷ 16.030
Outside diameter of standard tappets . . . . . . . . . . . . . . . . . . . . . . .
15.929 ÷ 15.959
Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.041 ÷ 0.101
87744428A − 11 − 2007
8
SECTION 10 − ENGINE − CHAPTER 1
ROCKER ARM − VALVE DATA
mm
Rocker−arm shaft diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18.963 ÷ 18.975
Rocker−arm shaft seat diameter . . . . . . . . . . . . . . . . . . . . . . . . . . .
19.000 ÷ 19.026
Rocker arm bore to shaft clearance . . . . . . . . . . . . . . . . . . . . . . . . .
0.025 ÷ 0.063
Valve clearance for normal running (engine cold): − inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.25 ± 0.05
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.50 ± 0.05
Cam lift: − inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.045
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.239
CYLINDER HEAD DATA Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm in cast iron with fitted valve seats and seats for injectors and thermostat valve
Maximum face re−grinding depth. that can be removed from the cylinder head in the event of reboring . . . . . . . . . . . . . . . . . . . . . . . . .
0.130
Diameter of valve stem seat in cylinder head . . . . . . . . . . . . . . . . .
8.019 ÷ 8.039
Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.960 ÷ 7.980
Assembly clearance between valve stem and seat . . . . . . . . . . . .
0.039 ÷ 0.079
Valve seat angle in head: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60°
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45°
Valve face angle: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60°
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
45°
Diameter on head for fitting valve seat: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
46.987 ÷ 47.013
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43.637 ÷ 43.663
Valve seat insert outside diameter: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
47.063 ÷ 47.089
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
43.713 ÷ 43.739
Valve stand−in relative to cylinder head face: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.00 ÷ 1.52
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.00 ÷ 1.52
Interference between valve seat and head: −
inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.050 ÷ 0.102
−
exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
0.050 ÷ 0.102 (continued)
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
9 (overleaf)
CYLINDER HEAD DATA
mm
Valve head diameter: − inlet valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
44.870 ÷ 45.130
− exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
41.870 ÷ 42.130
Inlet and exhaust valve springs: −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
63.500
−
length under load of 329 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
49.020
−
length under load of 641 N . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
38.200
Injector protrusion relative to head face: D BOSCH injectors 2856255 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Not adjustable
87744428A − 11 − 2007
10
SECTION 10 − ENGINE − CHAPTER 1
TORQUE SETTINGS WITH ANGLE Tightening torque PARTS TO BE TIGHTENED
Thread
Angle Nm
kgm
Main bearing cap bolts phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
50 ± 6
5.0 ± 0.6
−
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
80 ± 6
8.0 ± 0.6
−
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M12 x 1.5
−
−
90° ± 5°
phase 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
30 ± 3
3.0 ± 0.3
−
phase 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
60 ± 5
6.0 ± 0.5
−
phase 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
−
−
60° ± 5°
Bolts securing cylinder head . . . . . . . . . . . . . . .
M 12 x 1.75 x 70
50 ± 5
5.0 ± 0.5
90°
M 12 x 1.75 x 140
40 ± 5
4.0 ± 0.5
180°
M 12 x 1.75 x 180
70 ± 5
7.0 ± 0.5
180°
M 12 x 1.25
30 ± 4
3.0 ± 0.4
60° ± 5°
Big−end cap bolts
Note:
For the tightening sequence, see page 54, Fig. 120.
Bolts securing engine flywheel . . . . . . . . . . . . .
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
11
TORQUE WRENCH SETTINGS Tightening torque PARTS TO BE TIGHTENED
Thread
Bolts fastening pulley on crankshaft . . . . . . . . . . . . . . . . . . . . . Flywheel casing retaining bolts . . . . . . . . . . . . . . . . . . . . . . .
Nm
kgm
M 12 x 1.75
110 ± 5
11.0 ± 0.5
M 12 x 120
85 ± 10
8.5 ± 1
M 12 x 80
85 ± 10
8.5 ± 1
M 10 x 80
49 ± 5
4.9 ± 0.5
M 10 x 40
49 ± 5
4.9 ± 0.5
M 8 x 1.25
24 ± 4
2.4 ± 0.4
M 8 x 1.50
60 ± 9
6 ± 0.9
Oil sump threaded plugs . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 22 x 1.5
50 ± 5
5 ± 0.5
Rocker arm support retaining bolts . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Tappet cover retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Exhaust manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
53 ± 6
4.3 ± 0.6
Intake manifold retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Oil cooler retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Coolant pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Coolant inlet manifold retaining bolts . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
24 ± 4
2.4 ± 0.4
Thermostat valve assembly retaining bolts . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Fan support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25 x 50 M 10 x 1.50 x 25
10 ± 2 43 ± 6
1 ± 0.2 4.3 ± 0.6
Injector fastener . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
60 ± 5
6.0 ± 0.5
Fuel pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Nuts securing turbine mod. T4050 . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
43 ± 6
4.3 ± 0.5
Alternator retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.50
24 ± 4
2.4 ± 0.4
Starter motor retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.50
49 ± 5
4.9 ± 0.5
Camshaft plate retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Injection pump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
12 ± 5
1.2 ± 0.5
Oil pump gear casing retaining bolts . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
24 ± 4
2.4 ± 0.4
Additional counterweight retaining bolts . . . . . . . . . . . . . . . . .
M 10 x 1.5
48 ± 8
4.8 ± 0.8
Bolts securing camshaft gear . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
36 ± 4
3.6 ± 0.4
Oil sump retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87744428A − 11 − 2007
12
SECTION 10 − ENGINE − CHAPTER 1
SPECIAL 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 380000664
Splining tool for fitting rear seal on crankshaft.
X 380000665
Tool to extract crankshaft front seal.
X 380000666
Splining tool for fitting front seal on crankshaft.
X 380000667
Drift for camshaft bushing disassembly and reassembly (use with 380000668).
List of specific tools required for the various operations described in this Section. 380000668 X 380000216
380000220
X 380000221
380000301
X 380000302
380000304
380000362 X 380000364
Engine removal and installation tool. Clamp for fitting piston in cylinder liner (60−125 mm). Pliers for piston ring disassembly and reassembly (65−110 mm). Rotating stand for overhaul operations (capacity 1000 daN, torque 120 daN/m).
X 380000669
Gasket extraction tool.
X 380000670
Tool for cartridge filter disassembly.
380000671
Injector extraction tool.
380000975
Box with full set of tools to regrind valve seats.
380000976
Spring load test appliance.
380001003
Complete square to check for connecting rod distortion.
380001268
Belt tension gauge.
Tool for engine valve disassembly and reassembly. Pair of gauges for angular tightening with 1/2” and 3/4” square connection. Crankshaft lifting tool. Dial gauge base for various measurements (use with 380000228).
Grip for interchangeable drifts.
Injection pump bench test. 380000228
Dial gauge (0−5 mm).
X 380000732
Tool for engine flywheel rotation (use with 380000988).
Movable tool for dismantling tractors with bracket 380000500 and adapter plate 380000844.
X 380000914
Dial−gauge holder tool for rotary injection pump timing (use with 380000228).
X 380000661
Engine mounting brackets for rotating stand 380000301.
X 380000988
Plate for engine flywheel rotation tool with flywheel timing pin (use with 380000732).
X 380000663
Tool to extract crankshaft rear seal.
380000569
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
13
MIF1096A
1 Engine view
87744428A − 11 − 2007
14
SECTION 10 − ENGINE − CHAPTER 1
Oil path under pressure Oil return path under gravity MIF1098A
2 Engine lubrication diagram
Forced−circulation lubrication is accomplished by the following components: − oil pump, housed at the front of the crankcase, driven by the grooved bushing keyed onto the shank of the crankshaft; − water / oil cooler, housed in the crankcase;
87744428A − 11 − 2007
− − −
oil pressure control valve incorporated in the cooler assembly; by−pass valve to cut off clogged oil filter, incorporated in the cooler assembly; cartridge oil filter.
SECTION 10 − ENGINE − CHAPTER 1
15
Coolant recirculating in the engine Coolant entering the pump MIF1099A
3 Cooling diagram
The forced circulation, closed−circuit engine cooling system is composed of the following components: − a lubricating oil cooler;
− −
a centrifugal coolant pump housed at the front of the crankcase; a thermostat valve governing coolant circulation.
87744428A − 11 − 2007
16
SECTION 10 − ENGINE − CHAPTER 1
MIF1102A
4 Additional counterweight diagram
1. 2. 3. 4. 5.
Retaining bolts Support Retaining bolts Gear Balancing weight
87744428A − 11 − 2007
6. 7. 8. 9. 10.
Half bearings Counter−shaft Gear Ring O−rings
SECTION 10 − ENGINE − CHAPTER 1
17
5 Camshaft view A. Inlet valve cam.
B. Exhaust valve cam.
EXHAUST GAS RECIRCULATION SYSTEM (EGR)
The internal EGR system is not provided with any electronically controlled elements: the system is always on.
On the TIER 3 version, the exhaust cam profile has been modified to permit partial opening of the related valve during the inlet phase (exhaust gas recirculation EGR) with the consequent re−introduction of some of the exhaust gases into the engine cylinders. The exhaust gases can be partially redirected into the cylinders in order to reduce the maximum combustion temperature values which are responsible for the production of nitrogen oxide (NOx). The exhaust gas recirculation system (EGR), reducing the temperature of combustion by decreasing the concentration of oxygen in the combustion chamber, is therefore an effective system to control emissions of NOx.
Its configuration needs no additional elements such as control valves, pipes or heat exchangers. The exhaust cam (B) in addition to the main lobe has another lobe (see sect. A−A, fig. 5) with respect to the configuration without EGR. The additional lobe, during the inlet phase of the cylinder under examination, permits briefly opening the exhaust valve generating recirculation due to the exhaust gases returning caused by the lower pressure created in the inlet phase inside the cylinder.
87744428A − 11 − 2007
18
SECTION 10 − ENGINE − CHAPTER 1 TROUBLESHOOTING Problems
Engine does not start.
Possible Problem 1. Battery partially discharged. 2. Battery terminal corroded or loose.
Engine stalls.
Solutions Check and recharge Replace if necessary.
batteries.
connections Clean, inspect and tighten terminal nuts. Replace terminals and nuts if excessively corroded.
3. Injection pump timing incorrect.
Adjust injection pump timing on the engine.
4. Impurities or water in fuel lines.
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.
5. No fuel in tank.
Fill tank.
6. Fuel supply pump malfunction.
Check and necessary.
7. Air in fuel system.
Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system; then bleed the air from the circuit.
8. Starter motor faulty.
Repair or replace starter motor.
9. Thermostarter faulty.
Check and replace thermostarter if necessary.
1. Slow idling speed too low.
Adjust slow idling speed.
replace
pump
if
2. Injection pump delivery irregular. Check delivery on the test bench. 3. Impurities or water in fuel lines.
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.
4. Fuel filters clogged.
Replace the filter cartridges.
5. Incorrect valve − rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 6. Burnt or cracked valves.
Replace the valves.
7. Air in fuel system.
Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system; then bleed the air from the circuit.
8. Injection pump drive mechanism Replace damaged parts. damaged. (continued)
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
19 (overleaf)
Problems Engine overheating.
Possible Problem
Solutions
1. Coolant pump malfunction.
Overhaul pump necessary.
and
replace
if
2. Thermostat faulty.
Replace thermostat.
3. Radiator inefficient.
Remove internal deposits by flushing. Check for leaks and repair.
4. Deposits in cylinder head and Flush out coolant system. crankcase coolant passages. 5. Coolant pump and fan drive belt Check and adjust belt tension. slack. 6. Coolant level low.
Top up expansion tank with specified coolant mixture.
7. Incorrect engine timing.
Check and adjust engine timing.
8. Injection pump calibration Calibrate pump on test bench to incorrect − delivering too much or values specified in calibration tables. too little fuel. 9. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
Engine lacks power and 1. Injection pump timing incorrect. runs unevenly. 2. Auto advance regulator injection pump damaged.
Adjust injection pump timing on the engine.
in Overhaul injection pump and adjust on test bench to values specified in calibration table.
3. Control valve journal worn.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
4. Injection pump delivery irregular. Overhaul injection pump and adjust on test bench to values specified in calibration table. 5. All−speed governor damaged.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
6. Injectors partially obstructed or Clean, overhaul damaged. injectors. 7. Impurities or water in fuel lines.
and
calibrate
Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank. (continued)
87744428A − 11 − 2007
20
SECTION 10 − ENGINE − CHAPTER 1 (overleaf)
Problems
Possible Problem 8. Fuel supply pump damaged.
Solutions Replace fuel supply pump.
9. Incorrect valve − rocker arm Adjust the clearance between the clearances. rocker arms and the valves. 10. Cylinder compression low.
Test compression and engine if necessary.
overhaul
11. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
12. Tie−rod in linkage between Adjust to correct length. accelerator and injection pump incorrectly adjusted. 13. Fast idling speed screw on Adjust fast idling speed screw. injection pump incorrectly adjusted. The engine makes anomal- 1. Injectors partially obstructed or Clean, overhaul ous knocking noises. damaged. injectors.
and
calibrate
2. Impurities accumulating in fuel Clean fuel lines and replace severely lines. dented pipes; clean injection pump if necessary. 3. Injection pump timing incorrect.
Adjust injection pump timing on the engine.
4. Crankshaft knocking due to Re−grind crankshaft journals and excessive play in one or more crankpins. Fit oversize shell bearings main or big−end bearings or and thrust washers. excessive endfloat. 5. Crankshaft out of balance.
Check crankshaft alignment and balance; replace if necessary.
6. Flywheel bolts loose.
Replace any bolts that have worked loose and tighten all bolts to the specified torque + angle values.
7. Connecting rod axes not parallel. Straighten connecting rods, check axes parallelism; replace con rods if necessary. 8. Pistons knock due to excessive Rebore cylinder liners and fit oversize wear. pistons. 9. Noise caused by excessive play Fit oversize gudgeon pin, rebore of gudgeon pins in small−end and piston seats and small−end bushings. piston bushings. Loose fit of Replace with new bushings. small−end bushing. 10. Excessive tappet / valve noise.
Check for broken springs or excessive play between valve stems and guides, tappets and bores; adjust the clearance between valves and rocker arms. (continued)
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
21 (overleaf)
Problems
Possible Problem
Solutions
The engine produces 1. Maximum delivery of injection Calibrate pump on test bench to abnormal smoke: black or pump too high. values specified in calibration tables. dark grey. 2. Injection pump delivery Adjust injection pump timing or check excessively retarded or automatic advance regulator. automatic advance regulator damaged. 3. Injection pump excessively advanced. 4. Injectors partially obstructed or adjusted.
delivery Adjust injection pump timing on the engine.
or totally Clean, overhaul and calibrate incorrectly injectors; replace them if necessary.
5. Air filter clogged.
Clean the assembly and, if necessary, replace the filtering element.
6. Loss of engine compression due Replace damaged parts or, to: necessary, overhaul the engine. − piston rings sticking; − cylinder liner wear; − worn or incorrectly adjusted valves. 7. High−pressure damaged.
fuel
if
lines Inspect and replace if necessary.
Blue, grey−blue or grey− 1. Injection pump delivery Adjust injection pump timing or check white smoke. excessively retarded or automatic advance regulator. automatic advance regulator damaged. 2. Injectors obstructed or damaged. Clean, overhaul and calibrate injectors, replace if necessary. 3. Oil leaking past piston rings due Replace damaged parts or, to sticking rings or cylinder liner necessary, overhaul the engine. wear.
if
4. Oil leaking through the inlet valve Overhaul cylinder head. guides due to guide or valve stem wear. 5. Engine does not reach correct Replace thermostat. operating temperature (thermostat faulty). Engine runs switching off.
on
after 1. Engine stop damaged.
electromagnet Replace electromagnet.
2. All−speed governor damaged.
Overhaul injection pump and adjust on test bench to values specified in calibration table.
87744428A − 11 − 2007
22
SECTION 10 − ENGINE − CHAPTER 1
Op. 10 001 10 ENGINE 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.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. 1. Remove the bonnet as described in operation 90 100 22. 2. Extract the fixing pin and remove the ballast (1); unscrew the retaining screws and retrieve the ballast support (2).
6 3. Unscrew the retaining bolts and remove the side grille (1). Perform this operation on the other side of the tractor too.
7 4. Loosen the clamp (2), unscrew the retaining bolts and remove the exhaust silencer (1); the exhaust pipe remains secured to the cab.
8
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
23
5. Remove the guard (1) and disconnect the cables from the starter motor (2).
9 6. Disconnect the pipes (1) of the cab heating system and drain the engine cooling system.
10 7. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 42 litres).
25628
11 8. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
12
87744428A − 11 − 2007
24
SECTION 10 − ENGINE − CHAPTER 1
9. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
13 10. Unscrew the retaining bolts and remove the bonnet bracket (1).
14 11. Disconnect: the main electrical connections (1), the connection of the steering sensor and the cab ground, disconnect the throttle cable (2) from the injection pump.
15 12. Disconnect the diesel pipes (1) from the injection pump. Disconnect the pipe (2) from the pump.
16 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
25
13. Disconnect: the transmission oil cooler pipes (1) and the front axle differential lock pipe (2).
17 14. Unscrew the front, middle and rear retaining bolts and remove the propeller shaft guard (1).
27801
18 15. Remove the circlip (2) and move the front sleeve (1) backwards in order to free it from the groove on the front axle.
1
2
25647
19 16. Remove the circlip (2) and move the rear sleeve (1) in order to release it from the groove on the drive.
1
2
25646
20 87744428A − 11 − 2007
26
SECTION 10 − ENGINE − CHAPTER 1
17. Remove the propeller shaft central support (1) retaining bolts and extract the shaft together with the support.
1
25648
21 18. Loosen the retaining bolt and turn the bracket (1) through 90°.
22 19. For models fitted with brakes on the front axle it is necessary to drain the brake fluid tank and disconnect the pipes (1, 2 and 3) from the block.
23 20. Unscrew: the retaining bolts of the pipe (1) delivering oil to the pump and the bolts retaining the pipe (2) to the filter support.
24 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
27
21. Loosen the related clamps and remove the sleeve (2) from the pipe (1) and remove the transmission oil inlet pipe together with the above−mentioned sleeve.
25 22. Unscrew the retaining bolts and remove the guard (1). Do this on both sides.
26 23. Unscrew the retaining bolts and remove the cab mat guard (2). Remove the plastic pedal (1).
27 24. Unscrew the bolts (1) (on both sides), extract the spring pin (2) and remove the throttle pedal (3).
28
87744428A − 11 − 2007
28
SECTION 10 − ENGINE − CHAPTER 1
25. Raise the front part of the cab mat; remove the two plastic plugs and, through the hole (1), unscrew the four upper bolts securing the engine to the clutch casing.
29 26. Place a stand under the clutch casing, attach the rear portion of the engine to a hoist, using chains (1).
30 27. Unscrew the remaining bolts (1) securing the engine to the clutch casing and separate the engine with the front axle from the clutch casing.
31 28. Disconnect the connections (1) from the clogged air filter sensor.
32 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
29
29. Position two fixed stands: one under the axle support at the rear and the other under the front side. Keeping the chains (1,fig. 30) connected, join one chain (5) to the front of the engine. Unscrew the clamps and remove: The engine oil vapour recirculation pipe (3), turbocharger intake pipe (2), and the intake air cooler pipes (1 and 4).
33 30. Disconnect the lower (1) and upper sleeves from the radiator, remove the bracket (2) fastening the power steering pipe.
34 31. Insert a wooden wedge on each side between the axle support and the axle. For all models, unscrew the bolts (1) on both sides and separate the engine from the axle−support assembly with the radiator and battery. 32. Rest the engine on an adequate support. 33. To re−fit the engine, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
−
Apply the torque settings listed on page 12.
−
Connect the engine, with chains, to the hoist.
35
87744428A − 11 − 2007
30
SECTION 10 − ENGINE − CHAPTER 1
−
Refit the engine to the axle−support assembly with the radiator, battery, coolers: intake air and transmission oil.
−
Connect the upper and lower sleeves of the radiator to the engine.
−
Secure the power steering pipes.
−
Before refitting the engine to the clutch box carefully clean the mating surfaces and apply sealing compound (2 mm diameter), according to the diagram shown Section 21, Chapter 1, page 30.
−
Position the engine on the clutch casing and secure it with the specific bolts.
−
Fit the plastic plugs on the cab floor.
−
Move the cab mat into the right position and secure it with the two bolts on the upright (do this on both sides).
−
Connect the delivery pipe to the power steering pump.
−
Connect all the electrical connections between the cab and engine.
−
Position and secure the ground cable between the cab and engine.
−
Position and secure the throttle control rod.
−
Position the upper engine bracket with the heat guard and secure it.
−
Connect the front pipes to the rear pipes delivering coolant to the cab heater.
−
Position and secure the brake fluid tank and connect the electrical connection to the above−mentioned part.
−
Connect the steering control pipes.
−
Connect the electric cable to the starter motor and fit the relevant protection.
−
Fit the throttle pedal with the plastic part.
−
Position and secure the guard of the cab mat (do this on both sides).
−
Position and secure the heat shield, exhaust silencer to the engine and to the cab.
−
Fit the two lower guards of the control panel (do this on both sides).
−
Position and secure the side grille (do this on both sides).
−
Position, connect and secure the oil delivery pipe to the lift.
−
Secure: the radiator fixing bracket, engine oil vapour recirculation pipe, inlet pipe and intake air cooler pipes.
−
Position, connect and secure the lift control pump oil inlet pipe.
−
Connect the clogged air filter sensor pressure switch and steering sensor connections.
−
For models fitted with brakes on the front axle it is necessary to connect the pipes to the related block.
−
−
Position and secure the bracket between the clutch housing and engine.
For models fitted with brakes on the front axle it is necessary to fill the relevant tank (see sect. 00, page 6 for the prescribed product and quantity) and bleed the braking system (see sect. 33).
−
−
Position the propeller shaft, secure the central support, slide the two front and rear sleeves and secure them with the circlips.
Screw the plug on the rear transmission casing and fill up with oil (see sect. 00, page 6 for the prescribed product and quantity).
−
−
Position the propeller shaft guard and secure it.
Fill up the engine cooling system (see sect. 00, page 6 for the prescribed product and quantity).
−
Connect the differential lock control pipe.
−
Position and secure the ballast support.
−
Connect the pipes to the transmission oil cooler pipes.
−
Position and secure the ballast.
−
−
Connect the fuel supply and return lines to the injection pump.
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
31
Op. 10 001 54
ENGINE Disassembly − Assembly The figures refer to the F4CE9484M*J601 versions of 71 kW (97 hp) mod. T4050. The revision is to highlight and describe the specific parts of the versions F4CE9484N*J601 of 63 kW (86 hp) mod. T4040 and their respective variants.
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. Remove the engine as described in operation 10 001 10, proceed as follows. 2. Drain off the engine oil by removing the plug from the sump and the oil filler plug. 3. Detach the fan unit from the fan pulley. 4. To be able to fit the bracket 380000661 (for fixing the engine to the overhaul stand) to the crankcase, it is necessary to remove the wiring (1) from the left−hand side of the engine.
MIF1103A
36 5. To be able to fit the bracket 380000661 to the crankcase on the right−hand side, remove the starter motor (5), oil filter (3), clamp (4), and turbine oil return pipe (1). 6. Fix the gearbox to the rotating stand 380000301. Detach the oil delivery pipe (2).
MIF1104A
37
87744428A − 11 − 2007
32
SECTION 10 − ENGINE − CHAPTER 1
7. Remove the intake manifold (2). 8. Disconnect the engine oil vapour recovery pipe from the blow−by (3). 9. Remove the tappet covers (1). 10. Remove the pipes with the quick−fit coupling (6) and (8). 11. Remove the piping from the LDA system (5). 12. Remove the fuel filter (7). 13. Remove the heater (4). 14. Remove the control unit for the heater (10). 15. Remove the fuel filter support (9). MIF1105A
38 16. Remove the injector feed pipe (4) from the injection pump (3). 17. Remove the brackets on the cylinder head of the pipe assembly (1), (2) and (6). 18. Replace fuel supply pump (5).
MIF1107A
39 19. Detach the fuel pipe assembly (1) from the injectors. 20. Remove the fuel outlet pipe (2) from the injectors removing the screw (3) and the seal (4).
MIF1108A
40
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
33
21. Remove the screws (2) and the turbine (1). 22. Remove the exhaust manifold (3). 23. Remove the belt (3, fig. 42) of the auxiliary members by loosening the tightener.
MIF1109A
41 24. Remove the alternator (6), fan pulley (2) and the tightener (8). Remove the support (1) of the pulley (2) and the oil cooler (7). 25. Remove the coolant pump (5). 26. Remove the engine cooling system fitting (4) from the crankcase. NOTE: The coolant pump (5) cannot be overhauled. It must be replaced if there is any irregular operation.
MIF1110A
42 27. Lock the flywheel to stop it turning, remove the fixing screws (1) from the pulley (2).
MIF1111A
43 Removing the crankshaft front seal (Op. 28. ÷ 32.) 28. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 29. Perforate the inner seal (1) with a drill bit (j 3.5 mm) through the guide holes of the tool 380000665 (4), for a depth of 5 mm. 30. Secure the tool 380000665 (4) to the seal (1) with the screws (3) provided. 31. Extract the seal (1) by screwing down the screw (5). MIF0916A
44
87744428A − 11 − 2007
34
SECTION 10 − ENGINE − CHAPTER 1
32. Fit the tie rod (3) of the tool 380000669 to the outer seal (1) as shown in the figure 45 and with the lever (4), extract it from the front cover (2).
MIF0917A
45 33. Turn the engine over, take out the screws (2) and remove the oil sump (1).
MIF1117A
46 34. Take out the screws (2) and remove the oil pump (1).
NOTE: The oil pump (1) cannot be overhauled. It must be replaced if there is any irregular operation.
MIF1112A
47 35. Using the pin (1), lock the additional counterweights (2) at the T.D.C. Unscrew the retaining bolts (3) and remove the additional counterweights (2).
MIF1113A
48 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
35
36. Before removing the injection pump, do the timing and lock the engine flywheel with cylinder no.1 at T.D.C. as indicated on page 8, using tools 380000988 and 380000732. Then loosen the bolt (2), remove the “ L” spacer (1) and lock the screw (2) in order to keep the pump in time with the engine flywheel.
NOTE: Keep the ”L” spacer with the pump casing.
MIF0920A
49 37. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the crankcase (4) and extract it from its housing.
MIF0922A
50 38. Remove the screws (2) fixing the engine flywheel (1) to the crankshaft.
MIF1115A
51 39. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). 40. Extract the engine flywheel (1) so it can be slung with the lift and put it away in a specific container.
MIF1116A
52
87744428A − 11 − 2007
36
SECTION 10 − ENGINE − CHAPTER 1
Removing the crankshaft rear seal (Op. 41.÷ 44.) 41. Extract the seal, fitting the tool 380000663 (3) on the rear shank (1) of the crankshaft. 42. Perforate the inner seal (5) with a drill bit (j 3.5 mm) through the guide holes of the tool 380000663 (3), for a depth of 5 mm. 43. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 44. Extract the seal (5) by screwing down the screw (4). MIF0927A
53 45. Take out the screws (2) and remove the timing gear box (1), retrieving the injection pump gear.
NOTE: Note down the assembly position of the screws (2) as they have different sizes.
MIF1125A
54 46. Take out the screws (1) and remove the gears (3) and (4) from the camshaft (2).
MIF1118A
55 47. Take out the bolts (1) and remove the hydraulic pump drive gear (2).
MIF1119A
56 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
37
48. For each cylinder, remove the rocker arm assembly (1) loosen the adjuster nuts (3), unscrew the adjusters (4) and take out the screws (2).
MIF0933A
57 49. Extract the injectors (2) with tool 380000671 (1).
MIF0934A
58 50. Take out the screws (1) fixing the head to the crankcase.
1
MIF1120A
59 51. After fitting the brackets (1) and (2) hook the metal cables and detach the cylinder head from the crankcase with the hoist.
NOTE: After removing the cylinder head, remove the brackets (1) and (2).
MIF1121A
60
87744428A − 11 − 2007
38
SECTION 10 − ENGINE − CHAPTER 1
52. Valves are removed with tool 380000302 (1), applying pressure on the cap (3) so that, by compressing the springs (4), it is possible to remove the cotters (2). Then remove: the plate (3), springs (4). Repeat this operation on all valves (5).
MIF1122A
61 53. Remove the intake manifold cover and extract the oil seals (1) fitted on the valve stems. To remove the valves, turn the head over.
NOTE: Mark the inlet and exhaust valves before removing them.
MIF1123A
62 NOTE: The inlet valves differ from the exhaust valves in the size of the head and there being an additional reference mark (1) on the stem. A = Inlet valve. B = Exhaust valve.
MIF0948A
63 54. Remove the thermostat valve (2) from the governor body (1) taking out the screws (3).
MIF1124A
64 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
39
55. Take out the screws (1) securing the connecting rod caps (2) and remove them. 56. Extract the pistons together with the connecting rods from the top of the crankcase.
NOTE: Keep the half bearings in their respective housings since, if they are used, they must be mounted in the position found upon disassembly.
MIF0938A
65 57. Remove the rings (1) from the piston (3) with the pliers 380000221 (2).
MIF0950A
66 58. The piston pin (1) retaining snap rings (2) should be removed using a marking tool (3).
MIF0951A
67 59. Take out the screws (1) and remove the main bearing caps (2).
MIF1126A
68
87744428A − 11 − 2007
40
SECTION 10 − ENGINE − CHAPTER 1
60. The penultimate main bearing cap (1) and the related mounting have the half bearing (2) equipped with a shoulder. Remove the pistons with the connecting rods.
NOTE: Note down the assembly position of the top and bottom half bearings since, if they are reused, they must be mounted in the position found upon disassembly.
MIF0940A
69 61. Using tool 380000362 (1) and a hoist, remove the crankshaft (2) from the crankcase.
MIF1127A
70 62. Remove the main half bearings (1). 63. Take out the screws (2) and remove the oil nozzles (3).
MIF0942A
71 64. Take out the screws (1) and remove the plate (3) retaining the camshaft (2).
NOTE: Note down the assembly position of the plate (3).
MIF1128A
72 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
41
65. Carefully extract the camshaft (1) from the crankcase.
MIF1129A
73 66. Extract the tappets (1) from the crankcase.
MIF0945A
74 67. When disassembling and renewing the front and rear camshaft bushings (1) use the drift 380000667 (2) and grip 380000668 (3).
MIF1130A
75
87744428A − 11 − 2007
42
SECTION 10 − ENGINE − CHAPTER 1
GENERAL NOTES − −
−
After disassembling the engine, thoroughly clean the parts. Pages (42÷64) show the assembly operations that require extra attention in order to assemble parts correctly. The torque settings are shown on pages 10÷11.
ALSO REMEMBER THAT: − − −
When partially or fully disassembling the engine, all seals must be replaced. Before inserting rotating parts and seals in seats, lubricate the parts with engine oil. When fitting the oil filter, lubricate the seal with engine oil.
ATTENTION Handle all parts carefully. Do not put your hands or fingers between parts and use appropriate tools to align fixing holes. Wear the prescribed safety clothing, including goggles, gloves and safety footwear.
ENGINE ASSEMBLY ON THE BENCH FITTING THE BUSHINGS (Disassembly operation 67.) − To fit and renew the front and rear camshaft bushings (1) use the drift 380000667 (2) and grip 380000668 (3). NOTE: The bushings (1) must be directed so that the lubrication holes coincide with the holes in the seats in the crankcase. MIF1130A
76
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
43
FITTING THE TAPPETS (Disassembly operation 66.) − Lubricate the tappets (1) and fit them in their seats in the crankcase.
MIF1131A
77
FITTING THE CAMSHAFT (Disassembly operation 64. ÷ 65.) − Lubricate the bushings supporting the camshaft and mount the camshaft (1) taking care that, during this process, the bushings or the supporting seats do not get damaged.
MIF1129A
78 −
Position the plate (1) retaining the camshaft (2) with the slot facing towards the top of the crankcase and the punchmark facing the operator. Tighten the screws (3) to the prescribed torque stated on page 11.
MIF1132A
79 −
Check that the end float of the camshaft (1) comes within the tolerance range prescribed in Main Data on page 4.
MIF1133A
80
87744428A − 11 − 2007
44
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE OIL NOZZLES (Disassembly operation 63.) − Fit the nozzles (2) and tighten the retaining bolts (1).
MIF0957A
81
FITTING THE CRANKSHAFT (Disassembly operations 59. ÷ 62.) − If any sign of seizure, scoring or ovality is found on the main journals or crankpins, they must be reground. Before reconditioning the pins (1), use a micrometer (2) to measure the pins of the shaft and according to the undersizes given in Main Data on page 4, define the diameter to which the pins must be reduced.
MIF0958A
82 −
−
Check that the toothing of the grooved bushing (1), splined onto the crankshaft (2) is neither damaged nor worn; if it is, remove it with the a suitable extractor (3). When fitting the new grooved bushing it must be heated for 60 minutes in an oven at a constant temperature of 160 °C and spline it onto the crankshaft.
MIF1134A
83 NOTE: If the main journals of the crankshaft are undersized it is necessary to replace the main bearings of the same undersize class made. Do not modify the bearings in any way. The main bearings (1) are supplied as spare parts with an undersized inside diameter of 0.250 − 0.500 mm. Carefully clean the main half bearings (1) with a lubrication hole and fit them into their respective seats. The penultimate main half bearing (1) is equipped with semi−circular thrust washers.
87744428A − 11 − 2007
MIF0962A
84
SECTION 10 − ENGINE − CHAPTER 1 −
45
Fit the crankshaft (3) with the gear (1) and the grooved bushing (2).
MIF1135A
85 −
Check the clearance between the main journals of the crankshaft and their respective bearings, proceeding as follows: − Make sure that all parts are perfectly clean and remove all traces of oil. − Position a length of calibrated wire (3) on the crankshaft journals (4), parallel to the crankshaft centreline. − Fit the caps (1) complete with half bearings (2) on their supports.
MIF0964A
86 −
Insert the pre−lubricated screws (1) and tighten them in three successive stages. 1st and 2nd phase with a torque wrench to the torque given on page 10.
MIF0965A
87 −
3rd phase with tool 380000304 (1) positioned as in the figure, further tighten the screws (2) with an angle of 90° ± 5°.
MIF0966A
88
87744428A − 11 − 2007
46
SECTION 10 − ENGINE − CHAPTER 1
− Remove the support caps. The clearance between the main bearings and the relevant journals is measured by comparing the width of the calibrated wire (2), at the point of greatest crushing, with the graduation of the scale on the case (1) containing the calibrated wire. The numbers shown on the scale indicate the mating clearance in millimetres. Check that the clearance is as prescribed in Main Data on page 4, then lubricate the main bearings and permanently mount the supports, tightening the retaining bolts as described above. MIF1075A
89 The crankshaft end float is checked by placing a dial gauge (2) with a magnetic base on the crankshaft (3) as shown in the figure, the normal assembly clearance must come within the tolerance specified in Main Data on page 4. If the clearance is found to be any greater, change the main half bearings of the penultimate rear thrust bearing support (1) and check the clearance again between the crankshaft journals and main half bearings.
MIF1076A
90
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
47
FITTING THE CONNECTING ROD−PISTON ASSEMBLY (Disassembly operations 57. ÷ 58.) − The following references are cut into the crown of the piston: 1. Spare part number and design modification number; 2. Arrow showing the direction of assembly of the piston in the cylinder liner, it must face the front of the crankcase (auxiliary member side). 3. Date of manufacture. 4. Stamping indicating testing of the 1st groove insert. −
MIF0967A
91
Using the pin (3) connect the piston (2) to the connecting rod (4) so that the reference arrow (1) for fitting the piston (2) in the cylinder liner is facing as described in point 2.
MIF0968A
92 −
Insert the rings (2) retaining the pin (1).
MIF1060A
93 −
To fit the rings (1) on the piston (3) use tool 380000221 (2).
NOTE: The piston rings (see Main Data on page 4), are supplied as spare parts in the following sizes: − standard, marked with yellow paint; − oversized by 0.5 mm and marked with yellow/green paint.
MIF0969A
94
87744428A − 11 − 2007
48
−
SECTION 10 − ENGINE − CHAPTER 1
Fit the half bearings (1) on the connecting rod and cap.
NOTE: If the crankpins of the crankshaft are undersized it is necessary to replace the big end bearings of the same undersize class made. Do not modify the half bearings in any way.
MIF0970A
95
FITTING THE PISTON CONNECTING ROD ASSEMBLIES IN THE CYLINDER LINERS (Disassembly operation 56.) − Lubricate the pistons well, including the piston rings and the inside of the cylinder liners. − With the aid of the ring clamp 380000220 (2), fit the connecting rod−piston assemblies (1) in the cylinder liners.
MIF0971A
96 − − −
The ring openings must be staggered apart by 120°; The connecting rod/piston assemblies must all have the same weight; The arrow (1) stamped on the crown of the pistons must face the auxiliary member side of the engine and the recess in the piston skirt must correspond to the position of the oil nozzles.
MIF0972A
97 To measure the clearance proceed as follows: − Carefully clean the parts and remove all traces of oil; − Position a length of calibrated wire (2) on the crankshaft journals (1); − Fit the connecting rod caps (3) with the relevant half bearings (4).
MIF1077A
98 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
49
BIG END CAP ASSEMBLY (Disassembly operation 55.) − Tighten the screws (1) previously lubricated with engine oil with a torque wrench (2) to the torque prescribed on page 10.
MIF0973A
99 −
Fit tool 380000304 (1) on the socket wrench and further tighten the bolts (2) as prescribed on page 10.
MIF0974A
100 −
Remove the cap and determine the clearance by comparing the width of the calibrated wire (2) against the graduated scale printed on the packet (1) containing the wire. Check that the clearance is as prescribed in Main Data on page 4, then lubricate the big end half bearings and permanently mount them, tightening the connecting rod cap retaining bolts as described on page 10.
MIF1078A
101 NOTE: Before permanently fitting the connecting rod cap retaining bolts, check that their diameter, measured at the centre of the length of the thread, is no less than 0.1 mm of the diameter measured at approximately 10 mm from the end of the bolt. Check by hand that the connecting rods (1) run axially on the crankshaft journals and their end float measured with a feeler gauge (2) is as prescribed in Main Data on page 4.
MIF1079A
102
87744428A − 11 − 2007
50
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE THERMOSTAT VALVE (Disassembly operation 54.) − Assemble the thermostat valve (2) to its associated body (1) with the screws (3).
MIF1124A
103
FITTING THE CYLINDER HEAD (Disassembly operations 50. ÷ 53.) − Lubricate the valve stem and insert into the relevant valve−guides according to the position marked during disassembly. − Fit the seals (1).
1
MIF1137A
104 −
Position the following parts on the cylinder head: spring (4) and upper plate (3): using tool 380000302 (1) compress the spring (4) and fit the valve parts (5) using the cotters (2).
MIF1138A
105 − −
Check that the mating surfaces (1) of the cylinder head and crankcase are clean. Do not dirty the cylinder head gasket.
NOTE: Before reusing the cylinder head retaining bolts, check they show no sign of deterioration or deformation and replace them if they do.
MIF1009A
106 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
51
Using the dial gauge 380000228 (1) fitted with its base 380000364 (2), check the protrusion of the pistons (3) at T.D.C. from the cylinder block face is within the tolerance limits specified in Main Data on page 4.
MIF1080A
107 Since there are two type of head gasket, to choose its thickness (1.25 mm Type A and 1.15 mm Type B) make the following measurements: − for each piston, as shown in the figure, at a distance of 45 mm from the centre of the piston, measure its protrusions S1 and S2 from the top face of the crankcase and then calculate the mean: Scyl1 =
S1 + S2 2
Repeat this operation for pistons 2, 3 and 4 and calculate the mean value: S=
MIF1086A
108
Scyl1 + Scyl2 + Scyl3 + Scyl4 4
If S is > 0.40 mm use the gasket type A. If S is < 0.40 mm use the gasket type B. − −
Fit the lifting brackets to the cylinder head. Install the gasket, fit the cylinder head on the crankcase, screwing down the screws (1) without tightening them to torque.
MIF1139A
109 −
Before inserting the control rods, check that the spherical seat (1) of contact with the rocker arm adjuster screw and the spherical end (2) of contact with the tappet show no sign of wear; if there is, then change them. The inlet and exhaust valve control rods are identical and can therefore be interchanged.
MIF1011A
110
87744428A − 11 − 2007
52
−
SECTION 10 − ENGINE − CHAPTER 1
Spread LOCTITE 5999 sealant between the cover (2) and the manifold (3) and tighten the screws (1) to the torque prescribed on page 11.
MIF1094A
111
FITTING THE INJECTORS (Disassembly operation 49.) − On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3). − Fit the injectors 2, 3, 4 in the seats on the cylinder head and tighten them to the torque prescribed on page 11.
MIF1063A
112
FITTING THE ROCKER ARM ASSEMBLY (Disassembly operation 48.) − Check that the spindle (2) / rocker arm (1) coupling surfaces are neither too worn nor damaged.
Main spindle−rocker arm data (mm)
MIF1012A
113 −
−
Check that the tappet adjusters are unscrewed to prevent them sticking on the rods when fitting the rocker arm assembly (1). Then mount the rocker arm assembly comprising the support and spindles and secure them to the head without tightening the bolts (2) to torque. They will be tightened to torque together with those fixing the cylinder head.
MIF1013A
114 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
53
FITTING THE TIMING GEAR (Disassembly operation 46.) − Use a marker pen to mark the tooth of the driving gear (1) mounted on the crankshaft (2) on the side of which the reference mark (→) is stamped for timing.
MIF0977A
115 −
Direct the crankshaft (3) and camshaft (4) so that when mounting the driven gear (1) on the camshaft, the marks stamped on the gears (1 and 2) coincide.
MIF0978A
116 −
Place the dial gauge (1) on the timing gear (2) and check that the clearance between the gears (2) and (3) is between 0.076 ÷ 0.280 mm.
MIF1140A
117 −
Insert the screws (1) fixing the gears (2) to the camshaft (3) and tighten them to the torque prescribed on page 10.
MIF1141A
118 87744428A − 11 − 2007
54
−
SECTION 10 − ENGINE − CHAPTER 1
Tighten the cylinder head fixing screws in the sequence shown in Figure 120.
MIF1014A
119 −
Tightening sequence diagram for cylinder head bolts. 1st phase of tightening with torque wrench: M12 x 1.75 x 70 bolt: 50 Nm ÷ 5 Nm (ref. 3−6−11−14) M12 x 1.75 x 140 bolt: 40 Nm ÷ 5 Nm (ref. 1−2−7−8−9−10−15−16−17−18) M12 x 1.75 x 180 bolt: (ref. 4−5−12−13)
70 Nm ÷ 5 Nm
2nd phase additional tightening to an angle of 90° for 70 mm long bolts only or 180° for 140 e 180 mm long bolts only. A = fan side −
−
MIF1015A
120
Adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance is given in Main Data on page 4. Move the cylinder to the exhaust stroke and measure the clearance; the valves in the cylinder are closed, whilst those on the symmetrical cylinder are rocking. The symmetrical cylinders are 1 − 4 and 3 − 2. − FIRING ORDER 1 − 3 − 4 − 2 Balance valves of cylinder no.
1
Adjust valve clearance of cylinder no.
4
87744428A − 11 − 2007
3
4
2
MIF1016A
121 2
1
3
SECTION 10 − ENGINE − CHAPTER 1
55
FITTING THE INJECTION PUMP (Disassembly Operations 37. ) − Before fitting the injection pump, check that the engine flywheel is still locked and in time with cylinder no.1 at T.D.C. (as indicated in operation 36. page 35), using tools 380000988 and 380000732. − Do the timing for the injection pump (1, fig. 123) in relation to the drive gear, proceeding as described on page 4.
MIF0920A
122 −
−
Then loosen bolt (2), insert the ”L” spacer (1) and lock bolt (2) to make the fuel pump spindle free to turn. Fix the injection pump casing (1) to the seat of the gear box (2) with the screws (3).
MIF0981A
123 −
Spline the gear (1) transmitting drive to the pump.
1
MIF0982A
124
FITTING THE ADDITIONAL COUNTERWEIGHTS (Disassembly Operations 35.) −
After taking the first cylinder to the top dead centre and doing the timing of the gear of the timing system as described above, do the timing of the additional counterweights, making the marks (A) stamped on the gears coincide as shown in the figure.
MIF1142A
125 87744428A − 11 − 2007
56
−
SECTION 10 − ENGINE − CHAPTER 1
Insert the retaining pin in the hole (B) on the additional counterweight assembly to block rotation during the subsequent installation phase.
MIF1143A
126 −
Fit the additional counterweights (2), tighten the screws (3) to the torque prescribed on page 11 and remove the retaining pin (1) from the hole (B).
MIF1113A
127
FITTING THE HYDRAULIC PUMP DRIVE GEAR (Disassembly operation 47.) − Insert the gear driving the hydraulic pumps (2) into the seat and tighten the bolts (1).
1 2
MIF1144A
128
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
57
FITTING THE TIMING GEAR CASING (Disassembly operation 45.) − Carefully clean the timing gear box (1) and the crankcase. Cleaning the surface to seal is both necessary and unavoidable in order to obtain an effective seal. Apply LOCTITE 5205 sealant onto the box to form a bead with a diameter of a few mm as shown in fig. 129. It must be uniform (no lumps), with no air bubbles, thin areas or breaks. Any flaws must be corrected in as short a time as possible. Avoid using excess material to seal the joint. Too much sealant would tend to come out on both sides of the joint and clog the lubricant passageways. After applying the sealant, the joints require immediate assembly (max minutes). − Refit the box (1) to the crankcase. − Tighten the retaining bolts (2) in the position found during disassembly.
1
MIF1136A
129
MIF1147A
130
FITTING THE CRANKSHAFT REAR SEAL (Disassembly operations 41.÷ 44.) − Fit part (6) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (1) and spline the new seal (2) onto it. − Position part (5) on part (6), screw down the nut (4) until the seal (2) is completely fitted in the flywheel casing.
MIF1145A
131
FITTING THE FLYWHEEL (Disassembly operations 38.÷ 40.) − Check the clutch plate mating surface; turning is required if there is any scoring. − Check the state of the teeth of the crown gear (2). If you find any breakage or excessively worn teeth, replace it. Mount the new one, previously heated to a temperature of 150 °C for 15÷20 min. NOTE: The nominal thickness of the engine flywheel is 70.5 mm. MIF0990A
132
87744428A − 11 − 2007
58
−
SECTION 10 − ENGINE − CHAPTER 1
Screw two pins (2) of the appropriate length into the holes in the shaft (3) and, using the sling, mount the engine flywheel (1).
MIF1116A
133 − −
Spline the flywheel (1) onto the crankshaft, tightening the screws (2) by hand. Lock the flywheel appropriately before tightening the relevant screws to torque.
MIF1115A
134 −
Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page11: 1st phase, tightening with torque wrench to a torque of 30 ± 5 Nm; nd 2 stage, angle closed 60° ± 5°.
NOTE: Angle closing is performed with tool 380000304.
MIF1146A
135
FITTING THE OIL PUMP (Disassembly operation 34.) − Insert the seal. − Fit the oil pump (1). − Insert the tightening screws (2) and tighten them to the torque prescribed on page 11.
MIF1149A
136 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE OIL SUMP (Disassembly operation 33.) − Place the new seal on the crankcase. − Fit the oil sump (1). − Insert the screws (3) and tighten them to the torque prescribed on page 11. − Tighten the drain plugs (2) to the torque prescribed on page 11.
59
2
1
MIF1117A
137
FITTING THE CRANKSHAFT FRONT SEAL (Disassembly operations 28. ÷ 32.) − Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).
MIF1001A
138
FITTING THE CRANKSHAFT FRONT PULLEY (Disassembly operation 27.) − Spline the pulley (2) onto the crankshaft and tighten the screws (1) to torque and angle (see page 11), using tool 380000304.
MIF1111A
139
FITTING THE COOLING SYSTEM UNION (Assembly operation 26.) − Position the cooling system fitting so that the pins (3 and 4) are against the crankcase. − Tighten the screws (1 and 2).
MIF1005A
140 87744428A − 11 − 2007
60
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE COOLANT PUMP (Assembly operation 25.) − Fit a new seal (2) onto the coolant pump (1).
MIF0997A
141 − −
Mount the coolant pump (1). Screw down the screws (2) and tighten them to the torque prescribed on page 11.
MIF1150A
142
FITTING THE FAN−ALTERNATOR PULLEY (Disassembly operation 24.) − Fit the coolant temperature sensor (1) screwing it down with a torque wrench. − Fit the fan pulley support (2) with the screws (3), tightening them to the torque given on page 11.
MIF1151A
143 −
−
Fit on the crankcase: a new gasket (1), the cooler (2), a new gasket (3) and the oil filter mounting (5). Insert the screws (4) and tighten them to the torque prescribed on page 11.
MIF1152A
144 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
−
61
Refit the bracket (1) to secure the alternator (2) to the crankcase. Tighten the alternator fixing screws (3) to the torque specified on page 11.
MIF1006A
145 −
Fit the fan pulley (2) on the support (1) with the screws (3), tightening them to torque.
MIF1153A
146 −
Fit the tightener (1), tightening the bolts (2) and the tightener nut as directed on page 11.
MIF1154A
147
87744428A − 11 − 2007
62
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE AUXILIARY MEMBER DRIVE BELT (Disassembly operation 23.) − Fit the Poly−V belt (3) on the pulleys of the crankshaft, tightener (5) of the coolant pump (4), alternator (1) and fan (2). NOTE: Tension the belt correctly as indicated in operation 10 414 10.
MIF1155A
148
FITTING THE EXHAUST MANIFOLD − TURBINE (Disassembly operations 21. and 22.) − Mount the exhaust manifold (4) and tighten the screws (3) to the torque prescribed on page 11. − Fit the turbine (1) with the screws (2).
MIF1156A
149
FITTING THE INJECTOR FEED PIPES (Assembly operations 19. ÷ 20.) − Fit the injector feed pipe assembly (1). Fit the injector fuel outlet pipes (2), using the seals (4) and tighten the screws (3).
MIF1108A
150
FITTING THE FUEL PUMP − FEED PIPES (Disassembly operations 16. ÷ 18.) − Fit the fuel pump (5). − Fit the injector feed pipes (4) of the injection pump (3), secure the brackets fixing the pipe assembly (1), (2) and (6) on the cylinder head.
MIF1107A
151 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
63
FITTING THE PIPES BETWEEN THE FUEL SUPPLY AND INJECTION PUMPS, PRE−HEATING SYSTEM AND TAPPET COVER − − − − − − − − −
Fit the fuel filter mounting (9). Fit the control unit for the heater (10). Fit the heater (4). Fit the fuel filter (7). Fit the LDA system piping (5). Connect the pipes with the quick−fit coupling (6) and (8). Fit the tappet covers (1). Connect the engine oil vapour recovery pipe to the blow−by (3). Fit the intake manifold (2).
MIF1105A
152
87744428A − 11 − 2007
64
SECTION 10 − ENGINE − CHAPTER 1
FITTING THE STARTER MOTOR − −
Fit the oil delivery pipe (2). Fit the turbine oil return pipe (1), the clamp (4), oil filter (3) and starter motor (5).
MIF1104A
153 − − − −
Fit the wiring (1). Fit the fan unit to the fan pulley. Add engine oil through the filler plug. Install the bonnet as described in operation 90 100 22.
MIF1103A
154
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
65
CHECKS, MEASUREMENTS AND REPAIRS (CRANKCASE, CYLINDER LINERS)
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.
Checks and measurements After disassembling the engine, thoroughly clean the crankcase assembly. Use the specific lifting rings for transporting the assembly. Carefully check the crankcase is not cracked. Check the condition of the plugs (3, fig. 158) on the crankcase. If they are rusty or if there is the slightest doubt about their seal, change them. Examine the surfaces of the cylinder liners; they should show no scoring, ovality, taper or excessive wear. To check the internal diameter of the cylinder liners for ovality, taper and wear, use the bore gauge (1), fitted with a dial gauge zero−set on the ring gauge (2) of the diameter of the cylinder liner. NOTE: If the ring gauge is not available, use a micrometer.
MIF1030A
155 Measurements must be taken for each single liner at three different points on the liner and on two perpendicular faces: one parallel to the longitudinal axis of the engine (A) and the other perpendicular (B); maximum wear is generally found on this face in correspondence with the first measurement. If you find any ovality, taper or general wear outside the tolerance given in Main Data on page 4, bore and recondition the cylinder liners. The cylinder liners must be reground in relation to the diameter of the pistons supplied as spare parts (oversized by 0.5 mm over the nominal value) and to the assembly clearance prescribed in Main Data on page 4.
MIF1031A
156
87744428A − 11 − 2007
66
SECTION 10 − ENGINE − CHAPTER 1
MIF1032A
157 TOLERANCES
CHARACTERISTIC SUBJECT OF TOLERANCE
SHAPE
Cylindricity
ORIENTATION
Perpendicularity
POSITION
Location
/f/
− NOTE: If regrinding, all the liners must have the same oversize (0.5 mm). Check the main bearing seats, proceeding as follows: − fit the main bearing caps on the supports without bearings;
87744428A − 11 − 2007
GRAPHIC SYMBOL
tighten the retaining bolts to the prescribed torque; − using an appropriate dial gauge for interiors, check that the diameter of the seats is as prescribed in Main Data on page 4. If the measurement is any greater, change the crankcase.
SECTION 10 − ENGINE − CHAPTER 1
67
Check that the head mating surface, on the cylinder block, has no deformation. This check can be made, after taking out the grub screws (2), with a calibrated rule (1) and feeler gauge (4). After having located deformed areas, level off the mating surface using a grinding machine. The flatness error must be no greater than 0.075 mm.
NOTE: The crankcase can be faced only after making sure that, after machining, the protrusion of the piston from the cylinder liner is no greater than as prescribed in Main Data on page 4.
MIF1033A
158
Check the condition of the crankcase plugs (3); if they are rusty or if there is the slightest doubt about their seal, change them. After facing, restore the bevel of the cylinder liners as shown in Figure 157.
87744428A − 11 − 2007
68
SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS CRANKSHAFT
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.
Crankshaft Clean all parts carefully. If even slight cracks are found, replace the crankshaft. −
If any sign of seizure, scoring or ovality is found on the main journals or crankpins, they must be reground. Before reconditioning, use a micrometer (2) to measure the pins of the shaft (1) to define the diameter to which the pins must be reduced.
NOTE: It is advisable to note the values on a chart. See figure 160. −
The undersize classes are 0.250−0.500 mm. MIF0958A
159
MIF0959A
160 Chart on which to note the measurements of the main journals and crankpins (* Nominal value) All the main journals and crankpins must be ground to the same undersizing marked with a stamp on the side of the crank arm No. 1.
87744428A − 11 − 2007
Undersized crankpins with the letter M. Undersized main journals with the letter B. Undersized crankpins and main journals with the letters MB.
SECTION 10 − ENGINE − CHAPTER 1
69
MIF1158A
161 *
Measured on a radius greater than 45.5 mm.
** ½ 0.50 between adjacent main journals.
MAIN CRANKSHAFT TOLERANCES TOLERANCES SHAPE ORIENTATION POSITION OSCILLATION
CHARACTERISTIC SUBJECT OF TOLERANCE Circularity Cylindricity Parallelism Perpendicularity Straightness Concentricity or coaxiality Circular oscillation Total oscillation Taper
CLASS OF IMPORTANCE ASSIGNED TO PRODUCT CHARACTERISTICS
CRITICAL
GRAPHIC SYMBOL f /f/ //
GRAPHIC SYMBOL
IMPORTANT SECONDARY
87744428A − 11 − 2007
70
SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS − CONNECTING RODS
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.
Main data (mm) of the connecting rod, piston pin bushing and half bearings *
Inside diameter to be measured after installing in the small end and regrinding with a reamer. ** Cannot be measured free. NOTE: The connecting rod − connecting rod cap mating surfaces are knurled for a better coupling. It is therefore recommended not to remove the knurling. Each connecting rod is marked: − On the body and cap with a number indicating their coupling and the cylinder in which it is mounted. − In the event of replacement, number the new rod with the same number as the replaced connecting rod. On the body of the connecting rod with a letter indicating the weight class of the connecting rod mounted in production: − V, 1600g ÷ 1640g (marked in yellow); − W, 1641g ÷ 1680g (marked in green); − X, 1681g ÷ 1720g (marked in blue). Connecting rods are supplied as spare parts in class W and marked in green. Removing material is not permissible.
MIF1043A
162
Bushings Check that the bushing in the small end has not come loose and shows no sign of scoring or seizure. If this is not so, change it. Disassembly and assembly are performed with a suitable drift. When driving in, make sure that the oilways in the bushing and small end coincide. Using a boring machine, regrind the bushing to obtain the prescribed diameter.
MIF1044A
163
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
71
Checking connecting rods Check the parallelism of the connecting rod (2) axes using instrument 380001003 (4) as follows. Fit the connecting rod (2) on the self−centring spindle (3) of tool 380001003 (4) and lock it with the screw (5). Put the spindle (3) on the V” prisms, setting the connecting rod (2) on the stop bar (1).
MIF1045A
164 Checking twisting Check the twist of the connecting rod (2) by comparing two points (A and B) of the pin (4) on the horizontal plane of the connecting rod axis. Position the support (1) of the dial gauge (5) so that this pre−loads by ∼ 0.5 mm on the pin (4) at point A and reset the dial gauge (5). Move the spindle (3) with the connecting rod (2) and on the opposite side (B) of the pin (4) compare the difference: the variance between A and B must be no greater than 0.08 mm.
MIF1046A
165 Checking bending Check the bend of the connecting rod (3) by comparing two points (C and D) of the pin (4) on the vertical plane of the connecting rod axis. Position the vertical support (2) of the dial gauge (1) so that this rests on the pin (4) at point C as shown in the figure. Swing the connecting rod to and fro, seeking the highest position of the pin and reset the dial gauge (1) in this condition. Move the spindle with the connecting rod (3) and on the opposite side D of the pin (4) repeat the check for the highest point. The difference between points C and D must be no greater than 0.08 mm.
MIF1047A
166
87744428A − 11 − 2007
72
SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS PISTONS
2.560 2.605
105384
167 Normal dimensions (mm) piston data
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
73
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. Clean all parts carefully before proceeding with any type of operation. Measuring the piston diameter Using a micrometer (2) measure the diameter of the piston (1), and check the cylinder liners to determine the state of wear of the liners and pistons (see Main Data on page 4). If the clearance is not within the tolerances, it will be necessary to ream and rebore the liners and fit oversize pistons and rings (see Main Data on page 4).
NOTE: The diameter must be measured at a distance of 61 mm from the base of the piston skirt.
MIF1035A
168
Clearance between the piston and the cylinder liner can be measured with a feeler gauge (1), as shown in the figure 169.
MIF1036A
169 Piston pins Measuring the piston pin (2) diameter using a micrometer (1). Fit the pins on the pistons checking that the clearance between the piston pin and its bore in the piston is within the tolerance specified in Main Data on page 4.
MIF1037A
170
87744428A − 11 − 2007
74
SECTION 10 − ENGINE − CHAPTER 1
Conditions for correct pin−piston coupling Lubricate the pin (1) and the piston pin boss seat with engine oil; the pin must go into the piston with a light pressure of the fingers and must not drop out.
MIF1038A
171 Piston rings Using a micrometer (1) check that the thickness of the 1°−2°−3° ring (2) comes within the tolerances stated in Main Data on page 4.
MIF1039A
172 Using a feeler gauge (2), check that the clearance between the rings and their seats on the piston come within the tolerances prescribed in Main Data on page 4.
MIF1040A
173 Measuring the clearance X of the V−ring Due to the special shape of the first seal with a trapezoidal cross−section, the clearance between the groove and the ring should be measured as follows; make the piston (1) protrude from the crankcase so that the ring (3) at issue comes approximately halfway out of the cylinder liner (2). In this position, using a feeler gauge, check the clearance (X) between the ring and the groove: this clearance must be as prescribed in Main Data on page 4. MIF1041A
174 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
75
Measure the clearance between the ends of the piston rings (2) introduced in the cylinder liner (3) using a feeler gauge (1), checking it is as prescribed in Main Data on page 4.
MIF1042A
175
87744428A − 11 − 2007
76
SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS − VALVES AND CAMSHAFT
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. Clean all parts carefully before proceeding with any type of operation. Dimensions (mm) of valves and valve guides. A = Exhaust valve. B = Inlet valve.
MIF1048A
176 Decarbonizing, checking and grinding valves Remove all carbon deposits from the valves (2) using a wire brush (1). Check that the valves show no sign of seizure, cracks or burns. If necessary, grind the bevels on the valve heads using a grinding machine, removing as little material as possible.
MIF1049A
177 Using a micrometer (2) measure the valve stem (1) and check it comes within the range of tolerance given in Main Data on page 4.
MIF1050A
178
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77
MIF1052A
179 Dimensions (mm) valve seats
MIF1051A
180 Dimensions (mm) valve seat housings If the valve seats cannot be reconditioned by just regrinding, they can be replaced with the ones supplied as spare parts. Using a specific tool and taking care not to nick the cylinder head, remove as much material as possible from the valve seats until it is possible to extract them from the cylinder head with the aid of a punch.
Heat the cylinder head to 80 ÷ 100 °C and, using a suitable drift, insert the new valve seats, previously cooled. Then regrind the valve seats according to the values given in Figure 179. A = Exhaust valve. B = Inlet valve.
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SECTION 10 − ENGINE − CHAPTER 1
After regrinding, with the base 380000364 (2) and dial gauge 380000228 (1), check that the valve recessing (3) in relation to the top face of the cylinder head comes within the tolerance prescribed in Main Data on page 4.
MIF1053A
181
VALVE SPRINGS The figure shows the main data for checking the inlet and exhaust valve springs. Before assembly, check the valve spring flexibility using tool 380000976. Compare the elastic deformation and load data with those of the new springs stated in the following table.
H(free) H1 H2
Lift mm 63.50 49.02 38.20
Under a load of N No load P1 329 P2 641
MIF1054A
182
Tappets The figure gives the main data, in mm, of the tappets and their seats in the crankcase.
MIF1055A
183
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79
Camshaft
MIF1056A
184 Camshaft data The data refer to the normal journal diameter (dimensions mm) The support journal surfaces on the shaft and cams must be finely honed; if there are signs of seizing or scoring, replace the shaft and relative bushings. Checking cam lift and pin alignment Set the shaft on tailstocks and, using a dial gauge with a 1/100 mm scale placed on the central support, check that the alignment error is no greater than 0.04 mm; change the shaft if it is. Check the diameter of the supporting pins of the camshaft (2) with the micrometer (1) on two perpendicular axis.
MIF1057A
185
87744428A − 11 − 2007
80
SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS − CYLINDER HEAD
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. Use tool 380000302 to remove and refit valve springs. Clean all parts carefully before proceeding with any type of operation. Checking the cylinder head mating surface The mating surface of the head (1) with the cylinder block should be checked with a rule (2) and a feeler gauge (3). The deformation measured on the full length of the cylinder head must be no greater than 0.20 mm. If it is any higher, regrind the cylinder head according to the dimensions and warnings given in the following figure.
MIF1058A
186
Cylinder head thickness The nominal thickness A of the cylinder head is 95 ± 0.25 mm the maximum permissible amount of metal removed must not exceed the thickness B of 0.13 mm.
NOTE: After regrinding, check the valve recessing and if necessary regrind the valve seats to obtain the recessing prescribed in Main Data on page 4.
MIF1059A
187 TOLERANCES
CHARACTERISTIC SUBJECT OF TOLERANCE
SHAPE
Flatness
Cylinder head hydraulic seal check Check the hydraulic seal using the appropriate tools. Using a pump, introduce water heated to ∼ 90°C at a pressure of 2 ÷ 3 bar. If there is any leakage from the cup plugs, replace them, using a suitable drift for their disassembly − assembly.
87744428A − 11 − 2007
GRAPHIC SYMBOL
NOTE: Before fitting the plugs (3, fig. 158) apply a water−reactive sealant on their sealing surface. If you find any leakage from the cylinder head, it must be changed.
SECTION 10 − ENGINE − CHAPTER 1 LOW OIL PRESSURE Functional checks
INDICATOR
81
−
The device is composed of the control switch (1, fig. 188), engine oil pressure gauge (1, fig. 189) and the ”Stop” indicator (1). This indicator light (1) together with the red “Stop” indicator light (1) indicates the engine oil pressure is too low. Switch off the engine and look for the cause of the trouble. The indicator comes on under the following circumstances: −
low oil pressure (the indicator (1) lights up normally without there being any trouble, even with the engine warm and at low speed);
−
control switch (1, fig. 188) malfunction.
188
If the red lamp fails to illuminate when the engine is stopped and the ignition switch is turned to the power ON position, the possible causes are: −
blown fuse;
−
blown lamp;
−
interruption in wire to the control switch.
189
NOTE: When the engine oil pressure is too low, the indicator light comes on with the ignition key on B (ready for starting).
OIL FILTER − Replacement The oil filter is of the integral paper cartridge type. If the filter gets too clogged, the safety valve opens to enable the oil to by−pass the filter, keeping the engine lubricated, albeit with non−filtered oil. Replace the cartridge periodically (every 800 operating hours), remembering to: −
oil the outer part of the seal in contact with the mounting on the crankcase;
−
screw on the new cartridge until the seal is up against the mounting on the crankcase;
−
tighten the cartridge, by hand only, through a further 3/4 turn.
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SECTION 10 − ENGINE − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS − COOLING SYSTEM Clean all parts carefully before proceeding with any type of operation. The cooling system is fitted with a permanent coolant mixture consisting of water and ”AMBRA AGRIFLU” antifreeze (50% in volume). This mixture prevents freezing down to the following temperatures: Degrees °C
−8
−15
−25
−35
% in volume of ”AMBRA AGRIFLU”
20
30
40
50
When overhauling, remove deposits of lime scale in the radiator by means of a solution of water and descaling agent in the proportions shown on the container. It is never advisable to limit flushing to the radiator only − always extend this operation to the entire cooling circuit. Top up the engine with the solution referred to above. Run the engine for about an hour (with the engine off) in order to drain the solution through the drain plug. If the system is leaking, check the radiator seal by immersing it in a tank of water at a temperature of 20 ÷ 40 °C, blowing air into the radiator at a pressure of 0.98 bar (1 kg/cm2) for approx. two minutes (repeat the test at least three times).
This mixture also has anti−oxidant, anti−corrosion, anti−foaming and anti−scaling properties to ensure long−term protection of the cooling system.
COOLANT THERMOMETER − Check
The same mixture can be kept in the cooling system for a maximum of 2 years or 1200 operating hours, whichever comes sooner; after which it must be changed.
If malfunction is suspected, immerse the bulb of the thermometer in water and check the readings against a test thermometer (repeat the test a number of times with different water temperature to be sure).
RADIATOR − Flushing and checks Two valves are built into the radiator cap, one compression valve and one depression valve. Check the correct operation of the valves periodically.
THERMOSTAT VALVE − Replacement The thermostat valve is fitted in the cylinder head coolant outlet union. As calibration operations are not possible, the thermostat valve assembly will need to be replaced when it no longer satisfies the temperature data shown in the General Specifications tables on page 3.
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83
Op. 10 102 70 CRANKSHAFT FRONT SEAL Replacement
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.
To access the seal, proceed as follows: 1. Remove the bonnet as described in operation 90 100 22. 2. Remove the engine radiator, as indicated in operation 10 406 10. 3. Move the tightener (2) away to slacken the belt (1) and then remove it.
190 4. Remove the six retaining bolts (1), the pulley (2) governing the accessory assemblies and the fan−alternator−coolant pump pulley (3).
191
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SECTION 10 − ENGINE − CHAPTER 1
5. Apply tool 380000665 (4) on the front tang (2) of the crankshaft. 6. Perforate the inner seal (1) with a drill bit (j 3.5 mm) through the guide holes of the tool 380000665 (4), for a depth of 5 mm. 7. Secure the tool 380000665 (4) to the seal (1) by screwing down the screws (3) supplied. 8. Extract the seal (1) by screwing down the screw (5). MIF0916A
192 9. Fit the tie rod (3) of the tool 380000669 to the outer seal (1) as shown in the figure and with the lever (4), extract it from the front cover (2). 10. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
MIF0917A
193 To fit the front seal on the crankshaft, proceed as follows: −
Fit part (4) of tool 380000666 on the front shank (3) of the crankshaft. Secure it with the screws (5) and spline the new seal (6) onto it. Position part (1) on part (4), screw down the nut (7) until the seal (6) is completely fitted in the front cover (2).
−
Fit the fan−alternator−coolant pump pulley, the accessory assembly pulley and the six retaining bolts.
−
Refit the transmission belt on the pulleys, adjust it with the tensioning screw and lock the tightener, tightening the two retaining and pivot screws.
−
Refit the engine radiator as described in operation 10 406 10.
−
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
MIF1001A
194
SECTION 10 − ENGINE − CHAPTER 1
85
Op. 10 102 74 CRANKSHAFT REAR SEAL Replacement
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. To access the seal, proceed as follows: 1. Remove the clutch as described in operation 18 110 10.
195 2. Remove the eight screws (1) fixing the engine flywheel (2).
196 3. Screw two pins (2) of the appropriate length into the holes in the crankshaft (3). Slightly extract the engine flywheel (1) so it can be slung and then and put down in a specific wooden container with the hoist.
MIF1116A
197
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SECTION 10 − ENGINE − CHAPTER 1
4. Apply tool 380000663 (3) on the rear shank (1) of the crankshaft. 5. Perforate the inner seal (5) with a drill bit (j 3.5 mm) through the guide holes of the tool 380000663 (3), for a depth of 5 mm. 6. Secure the tool 380000663 (3) to the seal (5) by screwing down the screws (2) supplied. 7. Extract the seal (5) by screwing down the screw (4). MIF0927A
198 8. To assemble, proceed as follows:
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
To fit the front seal on the crankshaft, proceed as follows: 9. Fit part (6) of tool 380000664 on the rear shank (3) of the crankshaft. Secure it with the screws (1) and spline the new seal (2) onto it. Position part (5) on part (6), screw down the nut (4) until the seal (2) is completely fitted in the flywheel casing.
MIF1145A
199 10. With a hoist and appropriate slinging, insert the engine flywheel (1) on the pins (2) described above, pushing it into contact with the crankshaft (3).
MIF1116A
200
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87
11. Manually tighten the bolts (2) retaining the flywheel (1) to the crankshaft.
MIF1115A
201 12. Tighten the bolts (1) securing the engine flywheel (2) in two stages as described on page 10: − 1st phase, tightening with torque wrench to a torque of 30 ± 4 Nm; − 2nd stage, angle closed 60° ± 5°. NOTE: Angle closing is performed with tool 380001001.
MIF1146A
202 13. Refit the clutch as described in operation 18 110 10.
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SECTION 10 − ENGINE − CHAPTER 1
Op. 10 106 12 ADJUSTING VALVE/ROCKER ARM CLEARANCE Adjustment
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. Remove the bonnet (1) as described in operation 90 100 22. 2. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
203 3. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
204 4. Unscrew the retaining bolts and remove the bonnet bracket (1).
205
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89
5. Loosen the clamp and disconnect the engine oil vapour recovery pipe from the blow−by. Unscrew the relevant bolts and remove the tappet covers (1, 2 and 4).
206 6. After taking off the covers, adjust the clearance between the rocker arms and valves using an Allen wrench (1), box wrench (2) and feeler gauge (3). The working clearance should be: − inlet valves = 0.25 ± 0.05 mm − exhaust valves = 0.50 ± 0.05 mm. 7. Take the cylinder where the clearance is to be adjusted into the end−of−compression phase; the valves in the cylinder are closed, whilst those on the symmetrical cylinder are rocking.
MIF1016A
207 −
The symmetrical cylinders are 1 − 4 and 3 − 2.
−
FIRING ORDER 1 − 3 − 4 − 2 Balancing valves of cylinder no.
1
3
4
2
Adjust valve clearance of cylinder no.
4
2
1
3
Refit the parts that were removed, proceeding as follows. −
Respect the tightening torques prescribed on page 11.
−
Position the tappet covers with the seals and secure them.
−
Reconnect the engine oil vapour recovery pipe to the blow−by.
−
Position the upper engine bracket with the heat guard and secure it, connect the power steering pipes.
−
Position the brake fluid tank and secure it to the upper engine bracket, connect the related electrical connection.
−
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
90
SECTION 10 − ENGINE − CHAPTER 1
Op. 10 218 30
INJECTORS 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.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows: 1. Remove the bonnet (1) as described in operation 90 100 22. 2. Disconnect the power steering pipes (2), unscrew the related retaining bolts and remove the bracket (1).
208 3. Disconnect the electrical connection from the brake fluid reservoir (1), unscrew the retaining bolts and remove the reservoir from the supporting bracket.
209
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91
4. Unscrew the retaining bolts and remove the bonnet bracket (1).
210 5. Loosen the clamp (2), unscrew the retaining bolts and remove the exhaust silencer (1); the exhaust pipe remains secured to the cab.
211 6. Loosen the clamp and disconnect the engine oil vapour recovery pipe (3) from the blow−by. 7. Unscrew the relevant bolts and remove the tappet covers (1, 2 and 4). 8. Detach the fuel recirculation pipe from the injectors (5). 9. Disconnect the injector delivery pipes (6).
212 10. Remove the injectors (2) with tool 380000982 (1) and extract them from the cylinder head.
MIF1062A
213
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SECTION 10 − ENGINE − CHAPTER 1
11. To refit the injector, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
−
On the injector (1), mount a new seal (2) lubricated with Vaseline and a new washer (3).
−
Fit the injectors in the seats on the cylinder head and tighten them with a torque wrench to the torque prescribed on page 11.
−
Fit the new seals on the injector delivery pipe unions.
−
Connect the delivery pipes to the injectors.
−
Refit the tappet covers with their seals.
−
Reconnect the engine oil vapour recovery pipe to the blow−by.
−
Connect the injector fuel recovery pipe.
−
Position and secure the exhaust silencer.
−
Position the upper engine bracket with the heat guard and secure it, connect the power steering pipes.
−
Position the brake fluid tank and secure it to the upper engine bracket, connect the related electrical connection.
−
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
MIF1063A
214
SECTION 10 − ENGINE − CHAPTER 1
93
Op. 10 246 14 BOSCH INJECTION PUMP Removal−Installation, timing and air bleeding
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.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Remove the bonnet as described in operation 90 100 22. 2. Disconnect the fuel inlet pipe (1), return pipe (3), delivery pipe (4) and the pipe (1) from the injection pump. Disconnect the electrical connections (5 and 6).
215 3. Disconnect the fuel recirculation pipe (1) from the injectors. Unscrew the retaining bolts and remove the throttle control cable bracket (2). Disconnect the injector delivery pipes (3).
216
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SECTION 10 − ENGINE − CHAPTER 1
4. Disconnect the hydrostatic steering control valve supply pipe (1) and unscrew the injector delivery pipe bracket retaining bolt (2), disconnect the pipes from the injectors and remove them.
217 5. Before removing the pump, do the timing at T.D.C. as indicated on page 96 loosen the bolt (2), remove the ”L” spacer (1) and lock the screw (2) in order to keep the pump in time with the engine flywheel. NOTE: Keep the ”L” spacer with the pump casing.
MIF0920A
218 6. Remove the three nuts (2) (3) (5) securing the injection pump (1) to the crankcase (4) and extract it from its housing. 7. To refit the injection pump, proceed as follows. 8. Respect the tightening torques prescribed on page 11.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. MIF0922A
−
Keep to the timing described on page 96.
−
Make sure there are the disassembly conditions: at T.D.C. with the flywheel locked by tool 380000988 then position the injection pump on the crankcase and secure it with the specific bolts.
−
Loosen the screw (2, fig. 218) and insert the ”L” spacer (1).
−
Position and connect the delivery pipes to the injectors.
87744428A − 11 − 2007
219
SECTION 10 − ENGINE − CHAPTER 1
95
−
Disconnect the hydrostatic steering control valve supply pipe.
−
Connect the electrical connections for stopping the engine and for the advance device.
−
Position and secure the throttle control rod retaining bracket.
−
−
Connect the recirculation pipe from the injectors to the injection pump.
Connect the piping for the fuel supply pump, return to the tank and for connecting the fuel supply pump and the injection pump.
−
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
96
SECTION 10 − ENGINE − CHAPTER 1
Checking injection pump timing 1. If it is necessary to change the fuel pump, it is supplied already pre−set as a spare part. 2. Remove the starter motor (2), taking out the bolts (1).
MIF1172A
220 3. Fit the bracket of tool 380000988 (1) retaining the flywheel together with the rotation wheel 380000732 (3). 4. Carefully turn the flywheel in its direction of rotation to cancel the clearances of the gears. 5. Turn the engine until the pin (2) supplied with tool 380000988 engages through the slot in the flywheel (4).
MIF1173A
221 6. Unscrew the retaining bolts (2) and remove the priming pump (1) from the crankcase (3).
MIF1174A
222 7. Check through the seat of the priming pump that the camshaft (1) is in step (at TDC) using the reference marks (2) on the shaft. If the marks are not evident, withdraw the pin from the flywheel and rotate the engine 360° until the reference marks are visible. Re−insert the pin to lock.
MIF1175A
223 87744428A − 11 − 2007
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97
8. When fitting the fuel pump on the engine, it is necessary to bring about the condition of T.D.C. on cylinder No. 1 as described on the previous page 9. Fit the injection pump casing (1), preset, in the seat of the gear box (2) and secure it, without tightening, with the screws (3).
ATTENTION The seal removed at the time of pump disassembly must not be reused. Always use genuine spare parts. MIF0981A
224 10. Partly unscrew the bolt (1) locking pump spindle rotation and insert the spacer washer (2). Tighten the screw locking the above−mentioned washer: in this way, the fuel pump spindle is free to turn. 11. Extract the pin of the engine flywheel locking tool. 12. Remove tool 380000988 for flywheel locking/rotation; place the starter motor in its seat.
MIF1176A
225 13. With the injection pump in position but with the mounting bolts loose, remove the plug on the pump cover. 14. Fit the dial gauge 380001004 (2) and the associated tool 380000229 (1), pre−loading the shaft by 2.5 mm. 15. Turn the crankshaft to move from the condition of 1st cylinder at TDC. Reset the dial gauges and turn the crankshaft in the opposite direction to bring it back into the condition of the 1st cylinder at TDC in the phase of the end of compression. In this position the dial gauge on the pump must read off a value of 1.15 ± 0.05 mm. 16. Turn the pump anti−clockwise if the plunger has completed a shorter stroke, and clockwise if the stroke is longer, repeating the test until the correct stroke is obtained. 17. Verifying these conditions, lock the pump by tightening the relevant nuts to the torque shown on page 11.
MIF1165A
226
87744428A − 11 − 2007
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SECTION 10 − ENGINE − CHAPTER 1
18. Fit the priming pump (1) on the crankcase (3) and tighten the retaining bolts (2) to the prescribed torque.
MIF1174A
227
BOSCH INJECTION PUMP Fuel circuit air bleeding 19. Take out the bleed screw (1) on the filter. 20. Operate the fuel pump lever (2) until fuel (without bubbles) comes out of the filter then put the screw (1) back in.
MIF1166A
228 21. Loosen the injector delivery union (1), start the engine and, after having checked that there are no air bubbles, tighten the union (1).
1
MIF1167A
229
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
99
Op. 10 402 10
COOLANT PUMP 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. 1. Remove the engine radiator as indicated in operation 10 406 10. 2. Retrieve the duct (1), unscrew the retaining bolts and remove the fan (2).
230 3. Move the tightener (2) away to slacken the belt (1) and then remove it.
231 4. Disconnect the heater pipe (1) and remove it.
232
87744428A − 11 − 2007
100
SECTION 10 − ENGINE − CHAPTER 1
5. Unscrew the relevant retaining bolts and remove the coolant pump (1).
233 6. To install the coolant pump, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
−
Respect the tightening torques prescribed on page 11.
−
Fit a new seal (2) onto the coolant pump (1).
−
Position and secure the coolant pump.
−
Position and secure the heater pipe.
−
Position the belt and adjust its tension.
−
Position and secure the fan.
−
Position the duct.
−
Refit the engine radiator as described in operation 10 406 10.
87744428A − 11 − 2007
MIF0997A
234
SECTION 10 − ENGINE − CHAPTER 1
101
Op. 10 402 30 THERMOSTATIC VALVE 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.
1. Raise the bonnet. Unscrew the retaining bolts and remove the side grille (1).
235 2. Unscrew the plug (1) to drain off some of the coolant.
236 3. Loosen the clamp (1) and detach the sleeve (2) from the thermostat valve (3).
237
87744428A − 11 − 2007
102
SECTION 10 − ENGINE − CHAPTER 1
4. Remove the bolts (1) retaining the thermostat valve cover. 5. Remove the governor body (2), thermostat valve cover seal (3) and thermostat valve (4).
MIF1169A
238 6. To refit the thermostat valve, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS. −
Respect the tightening torques prescribed on page 11.
−
Position the thermostat valve, seal and cover, lock it all with the screws.
−
Connect and secure the sleeve to the thermostat valve.
−
Screw the plug onto the lower union.
−
Position and secure the side grille.
−
Fill up the engine cooling circuit (see sect. 00, page 6 for the prescribed product and quantity).
87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
103
Op. 10 406 10
RADIATOR 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. 1. Remove the bonnet (1) as described in operation 90 100 22. 2. Unscrew the retaining bolts and remove the side grille (1). Perform this operation on the other side of the tractor too.
239 3. Loosen the clamps (2) and (3), remove the sleeves (1) and (4) from the radiator and drain the fluid from the cooling circuit, leave the sleeves detached.
240 4. Unscrew the related retaining bolt and loosen the guide (1), unhook the catch and take out the condenser (2).
241
87744428A − 11 − 2007
104
SECTION 10 − ENGINE − CHAPTER 1
5. Disconnect the connection (1) from the clogged air filter sensor pressure switch. Disconnect the intake sleeve from the air cleaner.
242 6. Unscrew the retaining screw (1) and remove the air cleaner (2).
243 7. Detach the maxi fuses (1) from the related bracket.
244 8. Unscrew the related clamp and detach the pipe (2), unscrew the fixing screws and disconnect the expansion tank (1).
245 87744428A − 11 − 2007
SECTION 10 − ENGINE − CHAPTER 1
105
9. Unscrew the clamps and disconnect the pipes (1), (2), (3) and (4) from their seats.
246 10. Unscrew the retaining bolts and remove the cooler (1).
247 11. Unscrew the relative bolt and remove the bracket (1) securing the power steering pipes.
248 12. Unscrew the retaining bolt and remove the bracket (1) from the radiator.
249 87744428A − 11 − 2007
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SECTION 10 − ENGINE − CHAPTER 1
13. Unscrew the duct retaining bolts, unscrew the retaining bolts (1) and remove the radiator. 14. To refit the radiator, proceed as follows.
ATTENTION Use suitable tools to align the holes. NEVER USE FINGERS OR HANDS.
−
Respect the tightening torques listed on pages 10 and 11.
−
Position the radiator and secure with the relevant bolts.
−
Connect the two upper and lower sleeves to the radiator.
−
Secure the duct to the radiator.
−
Lock the retaining bracket to the radiator.
−
Position and secure the cooler.
−
Position the guide and the condenser and secure it all.
−
Secure the power steering pipes.
−
Position and secure the air cleaner.
−
Connect the engine vapour recirculation pipe.
−
Connect the intake sleeve to the rigid air cleaner pipe.
−
Connect the cooler pipes.
−
Connect the clogged air filter sensor pressure switch connection.
−
Position and secure the expansion tank and connect its pipe to the radiator.
−
Position and secure the maxi fuses.
−
Position and secure the supporting bracket and the side grille (do this on both sides).
−
Fill up the engine cooling system (see sect. 00, page 6 for the prescribed product and quantity).
−
Install the bonnet as described in operation 90 100 22.
87744428A − 11 − 2007
250
SECTION 10 − ENGINE − CHAPTER 1
107
Op. 10 414 10
4−CYLINDER COOLANT PUMP AND GENERATOR DRIVE BELT Tension adjustment (Disassembly operation 23.)
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. 251 Polyvee belt tensioning instructions To adjust the Polyvee belt (1) governing the fan − coolant pump − oil pump and alternator pulleys, proceed as follows: 1. Check that the belt (1) is correctly positioned on the belt tensioning device and on the pulleys. 2. Loosen the screws (2) and (3) retaining and pivoting the tightener to the cover (6). 3. Loosen the locking nut (5) and the screw for tensioning the belt (4), checking that its thread is not defective and has no oxidized/painted parts that would affect its rotation in its seat in the cover (6). 4. Turn the screw (4) and lightly tension the belt (1) with the tightener. 5. Using a torque wrench, adjust the tensioning screw of the belt (4) to the torque settings: 3.8 ÷ 4.4 Nm.
87744428A − 11 − 2007
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SECTION 10 − ENGINE − CHAPTER 1
6. Using a torque wrench, tighten the M10 nut (5) to a torque of 55 Nm (5.6 kgm). 7. Check the tension of the Polyvee belt in the position (1), shown in the figure 253 below, using the belt tension gauge 380001268, bearing in mind that the data measured must remain within the following tolerances: −
Assembly tension 1100 ÷ 1300 Nm
−
Frequency measured with gauge 380001268 158 P 170 Hz 252
8. If the measured data are out of tolerance, repeat operations 5 ÷ 7 described above and check that the measurements come within the prescribed tolerances. 9. Using a torque wrench, tighten the M10 nut (3) to a torque of 55 Nm (5.6 kgm). 10. Using a torque wrench, tighten the M8 nut (2) to a torque of 25 Nm (2.6 kgm).
NOTE: When fitting a new belt, check the tension again after 50 hours of running the engine.
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253
SECTION 18 − CLUTCH − CHAPTER 1
1
SECTION 18 − CLUTCH Chapter 1 − Clutch CONTENTS Section
Description
Page
18 000
General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
18 110 10
Clutch − Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
18 110 30
11”/11” Dual disk clutch − Test bench overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
18 110 30
11” Single disk clutch (Version with Power−Shuttle) − Test bench overhaul . . . . . . . . . . . 15
18 100 40
Clutch adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
LUK 11”/11” CLUTCH − GENERAL SPECIFICATIONS Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single disk, dry plate dual clutch unit
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
operation: pedal operated main transmission clutch; hand lever operated PTO 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 . . . . . . . . . . . . . . . . . . .
cerametallic
Driven plate thickness: −
main clutch (9, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mm
9,6 ÷ 10,4
−
PTO clutch (11, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
”
0.2874 to 0.3110 (7.3 to 7.9)
−
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
”
see pages 21 and 22
Clearance between main transmission clutch release sleeve and housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0019 to 0.0059 (0.050 to 0.151)
Clearance between PTO clutch release sleeve and housing . . . .
in. (mm)
0.0023 to 0.0053 (0.060 to 0.136)
Release lever coplanarity adjustment . . . . . . . . . . . . . . . . . . . . . . .
see pages 22 and 23
Clutch control adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 24
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2
SECTION 18 − CLUTCH − CHAPTER 1 LUK 11” CLUTCH − GENERAL SPECIFICATIONS
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
single dry plate clutch
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
operation with pedal
Engagement and release mechanism . . . . . . . . . . . . . . . . . . . . . . .
Belleville spring disk
Driven plate lining material for PTO clutch . . . . . . . . . . . . . . . . . . .
cerametallic pads
Driven plate thickness for PTO clutch (1, fig. 2) . . . . . . . . . . . . . . .
0.2874 to 0.3110 (7.3 to 7.9)
−
Driven plate wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clearance between clutch release sliding sleeve and support . . .
”
see page 21
in. (mm)
0.0019 to 0.0059 (0.050 to 0.151)
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
11”/11” clutch/flywheel retaining bolts . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
20 to 25
2 to 2.5
Release command fork securing bolt (7, fig. 1) . . . . . . . . . . . . . . .
M 16 x 1.5
136 to 165
13.9 to 16.1
Clutch casing/engine retaining nuts (3, fig. 1) . . . . . . . . . . . . . . . . .
M 12 x 1.25
117 to 129
11.6 to 13.1
Nut for sleeve cover fixing stud (6, fig. 1) . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
20 to 25
2 to 2.5
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 380001760
Pin for centring and adjustment of 11”/11” clutches.
X 380000293
Clutch adjustment (with 380001612).
380000256
gauge
Set of wrenches for adjustment of levers in 11”/11” LUK clutches.
87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
3
Longitudinal section of 11”/11” LUK clutch 1. PTO clutch release lever adjuster. 2. Belleville spring disc. 4. PTO clutch release levers. 8. Main clutch release lever. 9. Main clutch disk. 10. Main clutch release lever adjuster. 11. PTO clutch disk. D = 3.8385 in. (97.5 mm). Nominal distance of release levers (8) from clutch contact surface on flywheel. D1 = 5.4921 in. (139.5 mm). Nominal distance of release levers (4) from clutch contact surface on flywheel.
NOTE: During assembly apply sealing compound on surfaces marked with an X as shown in Section 21, Chapter 1, page 30.
1
87744428A − 11 − 2007
4
SECTION 18 − CLUTCH − CHAPTER 1 Longitudinal section of 11” LUK clutch
1. Main clutch disk. 2. PTO clutch release levers. D1 = 5.4921 in. (139.5 mm). Nominal distance of release levers (2) from clutch contact surface on flywheel.
NOTE: When refitting the clutch, check that the clutch disks are positioned as in the drawing.
NOTE: During assembly apply sealing compound on surfaces marked with an X as shown in Section 21, Chapter 1, page 30.
2
87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
5
CLUTCH TROUBLESHOOTING Problems Clutch slips
Possible Causes
Solutions
1. Worn disks 11 and 9, fig. 1, of Check and compare the data given on disk 1, fig. 2 on pressure the pages indicated, replace any plates and flywheel. parts which are worn up to or over the limit and adjust levers and clutch control linkage. 2. Belleville spring disk (2, fig. 1) Replace the Belleville spring disk. stretched or damaged. 3. Oil or grease contaminating the friction lining of disks (11 and 9, fig. 1) and of disk (1, fig. 2).
Fierce clutch
Replace the discs, identify and eliminate the source of lubricant inside the clutch housing and thoroughly clean the friction surfaces.
1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Clutch disk (9, fig. 1) de- Replace the disk and adjust the clutch formed. control lever. 3. Clutch disk (9, fig. 1) with Replace disk. damaged hub springs or loose hub rivets. 4. Oil or grease contaminating the friction lining of disks (11 and 9, fig. 1) and of disk (1, fig. 2).
Clutch sticks and drags
Replace the discs, identify and eliminate the source of lubricant inside the clutch housing and thoroughly clean the friction surfaces.
1. Clutch disks (11 and 9, fig. 1) Replace and adjust disks. and disk (1, fig. 2) deformed. 2. Seizure of external control Check, replace faulty parts and lubrilinkage. cate. 3. Controls incorrectly adjusted. Adjust the controls (see page 19).
Clutch noisy when engaged and/or disengaged
1. Thrust bearing worn.
Replace bearing.
2. Clutch disk (9, fig. 1) with hub Replace disk. springs damaged. Clutch pedal too stiff
1. Partial seizure of the external Check rod pivots and lubricate. control linkage. 2. Partial seizure of pedal pivot.
Check pivot and lubricate.
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6
SECTION 18 − CLUTCH − CHAPTER 1
Op. 18 110 10 CLUTCH 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. Check that no one is in the vicinity of the load to be lifted.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
Proceed as follows. 1. Carry out operation 90 100 22 Bonnet, only removal (see Section 90). 2. Remove the front ballast (3), if fitted, using a hoist and two steel cables (1), extract the pin (2) and remove the ballast. 27786
3 3. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 11.09 US gal. (42 litres).
25628
4 4. Disconnect the engine oil pressure sensor connection (1).
5
87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
7
5. Unscrew the speedometer/tachometer (2) control cable and the clamp (1). 6. Unscrew the bolt securing the exhaust pipe to the left−hand steps.
6 7. Disconnect the two steering cylinder control pipes (1).
7 8. Unscrew the relevant fixing clamp and detach the pipes (1 and 2) from the thermostarter and from the fuel pump.
8 9. Unscrew the brake fluid tank retaining bolts (2), remove the tank and attach to the RH handrail (1).
9
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8
SECTION 18 − CLUTCH − CHAPTER 1
10. Disconnect the engine electric connection (1).
10 11. Disconnect the thermostarter connection (1).
11 12. Disconnect the hydrostatic steering oil supply line (1).
12 13. Unscrew and detach the piping (1) from the filter. Loosen the relevant clamp and detach the piping (2).
13 87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
9
14. Disconnect the accelerator control cable (1) from the control lever. 15. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see Section 23).
14 16. Place a fixed stand under the front of the clutch casing, connect a chain to the rear hook on the engine and to the hoist and tighten it. 17. Wedge the front axle to avoid oscillation and then unscrew the clutch casing−engine retaining screws.
15 18. Operate on the front wheels and separate the clutch casing from the engine.
16 19. Using tool 380001760 (1), unscrew the retaining bolts and remove the clutch (2). 20. To refit the engine to the clutch casing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Apply the torque settings listed on page 2. 27785
17
87744428A − 11 − 2007
10 −
SECTION 18 − CLUTCH − CHAPTER 1 Before refitting the engine to the clutch casing carefully clean the mating surfaces and apply sealing compound (approx. 0.0787 in. (2 mm) diameter), according to the diagram shown Section 21, Chapter 1, page 33.
−
Secure the brake fluid reservoir to the intake manifold.
−
Connect and secure the pipes to the thermostarter and to the supply pump.
−
Refit the clutch to the flywheel, using tool 380001760.
−
Connect the steering cylinder control piping.
−
Using a hoist, position the engine−front axle assembly and secure in position.
−
Secure the exhaust pipe to the left−hand steps.
−
Connect and secure the speedometer/tachometer control cable.
−
Connect the engine oil pressure sensor connection.
−
Position and secure the ballast.
−
Carry out operation 90 100 22 Bonnet, only installation (see Section 90).
−
Tighten the rear transmission oil drainage plug and fill up with oil (see page 6, Section 00 for prescribed products and quantities).
−
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see Section 23).
−
Connect the throttle cable to the control lever.
−
Connect the lift delivery and inlet pipes to the transmission oil filter.
−
Connect the hydrostatic steering oil delivery pipe.
−
Connect the thermostarter and engine electrical connections.
87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1 Op. 18 110 30 Dual disk clutch 11”/11” − Test bench overhaul
11
1
CAUTION Always use appropriate tools to align fixing 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
18
1
2 24792
19 3. Position three clamps (1) at intervals of 120° on the clutch body and gradually and carefully squeeze the Belleville spring disk.
1
24793
20 4. Extract the six spring retaining pins (1) from their seats.
1
24794
21
87744428A − 11 − 2007
12
SECTION 18 − CLUTCH − CHAPTER 1
5. Remove the three clamps and extract the Belleville spring disk (1).
1
24975
22 6. Loosen the three locknuts (1) on the main clutch lever adjustment screws.
1
24976
23 7. Remove the three main clutch lever adjustment screws (1).
1
24977
24 8. Extract the main clutch pressure plate (1).
1
24978
25 87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
13
9. Extract the main clutch disk (1).
1
24979
26 10. Remove the springs (1) on the PTO clutch control levers.
1
24980
27 11. Extract the pivot pins (1) on the PTO clutch control levers.
1
24981
28 12. Remove the springs (1) on the main clutch control levers.
1
24982
29
87744428A − 11 − 2007
14
SECTION 18 − CLUTCH − CHAPTER 1
13. Extract the pivot pins (1) on the main clutch control levers.
1
14. To refit the clutch, proceed as follows.
CAUTION Always use appropriate tools to align fixing 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.
87744428A − 11 − 2007
24983
30
SECTION 18 − CLUTCH − CHAPTER 1
15
Op. 18 110 30 Single disk clutch 11” (fitted with Power− Shuttle) − Test bench overhaul
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Unscrew the three clutch lever adjustment nuts (1). 25963
31 2. Remove the pressure plate (1) with the coil springs (2) on the levers.
25964
32 3. Unscrew the six retaining bolts (1) of the Power Shuttle gear control disk and remove (2). 4. To refit the clutch, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Refit the Power Shuttle gear control disk in the clutch housing.
−
Install the pressure plates and secure to the spring coils.
−
Tighten the lever adjustment nuts.
25965
33
87744428A − 11 − 2007
16
SECTION 18 − CLUTCH − CHAPTER 1
CHECKS, MEASUREMENTS AND REPAIRS − DUAL DISK CLUTCH
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch A w 0.6102 in.; B w 0.8936 in.; D w 0.6220 in. (w 15.5 mm; B w 22.7 mm; D w 15.8 mm). 1. Flywheel. 2. PTO clutch pressure plate. 3. Main clutch pressure plate. 4. Clutch cover.
25966
34
Minimum permissible dimensions after refacing of parts subject to wear in the 11” single clutch A w 0.6102 in.; D w 0.6220 in. (w 15.5 mm; C w 15.8 mm). 1. Flywheel. 2. PTO clutch pressure plate. 3. Clutch cover.
−
Check the degree of wear on the PTO (11, fig. 1 and 1, fig. 2) and gear (9) clutch disks, replacing them if the linings have worn down (or are nearly worn down) to the rivet heads.
−
Replace the disk when the oil has soaked into the organic agglomerate surfaces.
25967
Minimum permissible dimensions after refacing of parts subject to wear in the 11”/11” dual clutch and 11” single clutch. −
Check the friction surface conditions of the pressure plates and the clutch cover. Generally, by means of turning, up to 0.0393 in. (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 Section 10 Chapter 1, page 56). When parts (1), (2), (3) and (4 figs. 34 and 35) are to be repaired by removing material, proceed as follows:
87744428A − 11 − 2007
35
SECTION 18 − CLUTCH − CHAPTER 1 −
17
If it is necessary to reface the friction surfaces on the PTO clutch pressure plate (2, fig. 34 and 35), 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. 34 and 35) 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. 34 and 35) 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. −
When the friction surfaces of the main clutch pressure plate (3, fig. 34) 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. 34), 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 11”/11” DUAL CLUTCH RELEASE 1. After overhauling the clutch, fit the centering pin 380001760 (1) and fit the entire clutch assembly to the flywheel, then tighten the bolts (2).
25968
36
87744428A − 11 − 2007
18
SECTION 18 − CLUTCH − CHAPTER 1
2. Fit gauge 380000293 (1) on the centering pin and, using a feeler gauge, adjust the clutch release levers (2) to obtain a clearance of 0.0039 in. (0.1 mm).
25969
37 3. Rotate the gauge 380000293 (1) and, using a feeler gauge, adjust the PTO clutch release levers (2) to obtain a clearance of 0.0039 in. (0.1 mm).
25970
38
COPLANARITY OF 11” SINGLE PLATE CLUTCH RELEASE LEVERS 4. After overhauling the clutch, fit centering pin 380001760 (1), gauge 380000293 (2), and fit the entire clutch assembly to the flywheel, then tighten the bolts (3).
25971
39 5. Using a feeler gauge, adjust the coplanarity of the clutch release lever to obtain a clearance of 0.0039 in. (0.1 mm).
25972
40 87744428A − 11 − 2007
SECTION 18 − CLUTCH − CHAPTER 1
19
Op. 18 100 40 CLUTCH ADJUSTMENTS
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. If the position of the clutch pedal (1) requires adjustment, or after a clutch overhaul, check that main clutch pedal travel (A), from the centre of the clutch pedal to the surface of the board, is 5.5118 ± 0.0787 in. (140 ± 2 mm). If not, adjust as follows: −
Loosen the locknut (2) and turn the nut (1) anticlockwise.
−
Check that the height of the pedal is 5.5118 ± 0.0787 in. (140 ± 2 mm).
−
Tighten the locknut (2).
−
Operate the unit four or five times.
−
Check that the height of the clutch pedal (1, fig. 41) is as prescribed.
−
If necessary, reset to the correct value (A, fig. 41) as previously described.
41
42
87744428A − 11 − 2007
20
SECTION 18 − CLUTCH − CHAPTER 1
PTO CLUTCH CONTROL ADJUSTMENTS
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
1. With the PTO lever (1) disengaged, using the external lever (4, fig. 44) (located on the clutch casing), move the internal lever into contact with the PTO clutch engagement sleeve. 43 2. Loosen the locknut (2), extract the pin (5), tighten the fork (1) on the control cable (3) until the cable is slightly tensioned, whilst making sure that the external lever (4) has not moved. 3. Carry out 5 engage/disengage manoeuvers and check that the conditions (in the points previously mentioned) have not changed. 4. Unscrew the fork (1) by half a turn (180°). 5. Tighten the locknut (2).
44 6. With the lever (1) disengaged, check that it is in contact with the relative stop (2).
45 7. Check that the clearance (L) between the lever (1) and the relative sector (2) is 0.1181 to 0.1968 in. (3 to 5 mm). If not, unscrew the sector (2) retaining bolts and position correctly.
46 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
1
SECTION 21 − TRANSMISSIONS Chapter 1 − Mechanical transmission (12 + 12) and (16 + 16) CONTENTS Section
Description
Page
21 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21 118 10
Rear transmission casing−gearbox. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . 17
21 118 12
Rear transmission casing−gearbox. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . 17
21 118 85
Gearbox transmission casing. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
REVERSER DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical type with spur gearing, located between the main clutch and the gearbox
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left−hand side of operator
CREEPER UNIT MAIN DATA (16 + 16 VERSION) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ordinary gear train with spur gearing, located between the main clutch and the gearbox, up stream from the reverser. Providing 28 forward gears and 16 reverse gears
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hand lever located on left−hand side of operator (continued)
87744428A − 11 − 2007
2
SECTION 21 − TRANSMISSIONS − CHAPTER 1 TRANSMISSION AND RANGE GEAR DATA (cont)
Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant−mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Range gear (16 + 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds
Range gear (12 + 12 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 3 ranges providing a total of 12 gears
−
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
spur
Gearbox and range gear operating system . . . . . . . . . . . . . . . . . . .
Thickness of gearbox driving shaft adjustment ring (4, figs. 7 and 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of driven shaft adjustment ring (12, figs. 7 and 8) . . . .
independent, by means of lever located on right−hand side of operator in. (mm)
0.0196 − 0.0295 − 0.0393 − 0.0492 − 0.0590 − 0.0688 − 0.0787 − 0.0885 (0.5 − 0.75 − 1.0 − 1.25 − 1.5 − 1.75 − 2.0 − 2.25)
in. (mm)
0.0196 − 0.0295 − 0.0393 − 0.0492 − 0.0590 − 0.0688 − 0.0787 − 0.0885 (0.5 − 0.75 − 1.0 − 1.25 − 1.5 − 1.75 − 2.0 − 2.25)
in. (mm)
1.6535 (42)
in. (mm)
1.3779 (35)
in. (mm)
1.7322 (44)
in. (mm)
1.3779 (35)
Springs for detent balls on gearbox and range gear control rods: −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
length of spring under load of 75.5 to 83.3 N 16.98 to 18.74 lbs. (7.7 to 8.5 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Springs (1, page 10) for gearbox and range gear control levers: −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
length of spring under load of 31.4 to 35.3 N 7.0579 to 7.9402 lbs. (3.2 to 3.6 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Sleeve cover retaining nuts (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
20 to 25
2.0 to 2.5
Gearbox driving and driven shafts bearing cover screws (C2) . .
M 10 x 1.25
84 to 93
8.6 to 9.5
Retaining bolts securing creeper clutch casing to rear transmission/gearbox (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
117 to 129
11.9 to 13.1
Driven gear shaft locknut (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 32 x 1.5
280 to 309
28.5 to 31.5
Drive gear housing cover retaining screws (C5) . . . . . . . . . . . . . .
−
43 to 51
4.4 to 5.2
Pressure switches (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
51 to 72
5.2 to 7.3
Parking brake inspection cover, gearbox and range control relay levers support cover retaining screws (C7) . . . . . . . . . . . . . . . . . .
M 10 x 1.25
43 to 51
4.4 to 5.2
Bolts or nuts securing creeper clutch casing to the engine (C8)
M 12 x 1.25
117 to 129
11.9 to 13.1
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
3
TIGHTENING TORQUES
C1 − 20 to 25 Nm
25612
C3 − 117 to 129 Nm
C4 − 280 to 309 Nm
C5 − 43 to 51 Nm
C2 − 84 to 93 Nm
C6 − 51 to 72 Nm
25614
C7 − 43 to 51 Nm
C8 − 117 to 129 Nm 27928
1
87744428A − 11 − 2007
4
SECTION 21 − TRANSMISSIONS − CHAPTER 1
TOOLS
X 380001614
Tool for gearbox driving and driven shafts adjustment.
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 380001615
Driving shaft rod for lifting unit.
X 380001616
Driven shaft retaining tool.
X 380001617
Pliers for gearbox shafts circlips.
380001618
Driving shaft fitting guide.
X 380001619
Driven shaft fitting guide.
X 380001610
Adjuster handle (with 380001620 and 380001609).
X 380001620
Power take−off drive shaft seal splining tool (with 380001610).
X 380001609
Power take−off drive shaft roller bearings splining tool (with 380001610).
List of specific tools required for the various operations described in this Section. 380000227
Clutch casing lift hook.
380000301
Rotating stand for overhaul operations.
24663
2 Tool to be made for disassembly−assembly of the final drives, to be used with 50114. (Mark part with No. 50091 − Measurements in mm) 1. Make 2 tie−rods in C 40 bon material. − Make in Aq 42 D material.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
5
26258
3 Tool to be made for lateral gear removal−installation, use with a part of 50091. (Mark part with No. 50114 − Measurements in mm) Make in Fe 42 C material − (*) Measurement according to hoist seat.
87744428A − 11 − 2007
6
SECTION 21 − TRANSMISSIONS − CHAPTER 1
1
4 Bracket to be made for gearbox overhaul on rotating stand. (Mark tool No. 50157 − Measurements in mm) 1. Rotating stand shaft. Make in Fe 42C material.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
7
5 Bracket to be made for gearbox overhaul on rotating stand. (Mark part with no. 50157 − Measurements in mm) Make in Fe 42C material.
25618
6 Guide pin for re−fitting the gearbox in the casing. (Mark part with no. 50158 − Measurements in mm) Make in C 40 material.
87744428A − 11 − 2007
8
SECTION 21 − TRANSMISSIONS − CHAPTER 1
7 Longitudinal cross−sectional view of gearbox and gear range (12 + 12) 1. 2. 3. 4. 5. 6. 7.
Seal. Power take−off shaft support roller bearings. Reverser control synchroniser. Gearbox driving gear clearance adjusting thickness. Power take−off shaft. Gearbox driving gear. Selector sleeve for high or medium−low speeds.
8. 9. 10. 11. 12.
Bevel pinion shaft. Selector sleeve for low gears. Synchroniser for 1st and 2nd speed. Synchroniser for 3rd and 4th speed. Gearbox driven shaft gear clearance adjusting thickness. 13. Gearbox driven shaft.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 33.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
1
2
3
4
5
6
7
9
8
X X 25619
13
12
11
10
9 8
Longitudinal cross−sectional view of gearbox and gear range (16 + 16) 1. 2. 3. 4. 5. 6. 7.
Seal. Power take−off shaft support roller bearings. Reverser control synchroniser. Gearbox driving gear clearance adjusting thickness. Power take−off shaft. Gearbox driving gear. Selector sleeve for high or medium−low speeds.
8. 9. 10. 11. 12.
Bevel pinion shaft. Selector sleeve for low or medium−high speeds. Synchroniser for 1st and 2nd speed. Synchroniser for 3rd and 4th speed. Gearbox driven shaft gear clearance adjusting thickness. 13. Gearbox driven shaft.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 33.
87744428A − 11 − 2007
10
SECTION 21 − TRANSMISSIONS − CHAPTER 1
9 Cross−sectional view of gearbox and range gear 1. 2. 3.
Shuttle control external rod. Gear control external rod spring. Gear control external rod.
4. 5.
Gear selector internal rod. Reverser selector internal rod.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 33.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
1
2
11
3 4
8
5
7
25621 25622
6
25623
10 Cross−sectional view of gearbox and range gear 1. 2. 3. 4.
Range gear control external rod spring. Range gear control external rod. Reverser control fork. Shuttle selector synchroniser.
5. 6. 7. 8.
Shuttle relay gear (reverse gear). Detent ball and spring. Lubricating oil external pipes. Lubricating oil internal pipes.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 33.
87744428A − 11 − 2007
12
SECTION 21 − TRANSMISSIONS − CHAPTER 1
27929
11 Longitudinal cross−sectional view of creeper unit for gearbox (16 + 16) 1. 2.
Creeper unit selector sleeve. Creeper unit driving shaft−gear.
87744428A − 11 − 2007
3. 4.
Creeper unit driven gear. Reverser selector synchroniser.
SECTION 21 − TRANSMISSIONS − CHAPTER 1
1
2
3
13
4
25750
5
25747
8
7
6
12 Cross−sectional view of gearbox with creeper (16 + 16) 1. 2. 3. 4.
Spring. Detent ball. Reverser control rod. Safety pawl.
5. 6. 7. 8.
Creeper control rod stop rings. Splitter device and creeper unit control rod. Detent ball. Spring.
87744428A − 11 − 2007
14
SECTION 21 − TRANSMISSIONS − CHAPTER 1
13 Cross−sectional view of gearbox with creeper (16 + 16) 1. 2. 3.
Shuttle control external rod. Gear control external rod spring. Gear control external rod.
4. 5. 6.
Gear selector internal rod. Creeper selector internal rod. Reverser selector internal rod.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 33.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
15
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 gear provides 3 forward gear (12 + 12 version) or 4 gear ranges (16 + 16). 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 + 12 version) or 16 forward gears and 16 reverse gears (16 + 16 version). It is controlled by a lever located on the cab platform to the left of the operator. 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 synchroniser located in the gear unit.
Lubrication is by means of the oil in the rear transmission casing/gearbox.
Creeper unit (16 + 16 version) The creeper unit is a mechanical device providing 28 forward speeds and 16 reverse speeds. The creeper unit only intervenes in slow, medium slow and medium fast ranges, a mechanical interlock prevents creeper engagement in the fast ranges. 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 same control lever as the reverser, located on the left−hand side of the operator.
The reverser is installed inside the clutch casing, between the clutch and the gearbox.
GEARBOX, CREEPER UNIT AND REVERSER TROUBLESHOOTING
Problems
Possible Causes
Solutions
Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. incorrectly adjusted. gearbox, creeper or reverser. 2. Control lever retaining springs Renew the springs. damaged. 3. Synchroniser teeth or selec- Remove the transmission−gearbox tion sleeves damaged. casing and replace the synchronisers or the sleeves. 4. Engagement stroke incom- Eliminate the cause and reset the plete. complete stroke. (continued)
87744428A − 11 − 2007
16
SECTION 21 − TRANSMISSIONS − CHAPTER 1 GEARBOX, CREEPER UNIT AND REVERSER TROUBLESHOOTING (cont)
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 seiz- Check rod pivots and lubricate. ure of external levers and relay rods. 3. Main clutch dragging.
See Section 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. easily: 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 TROUBLESHOOTING (16+16 VERSION) Problems
Possible Causes
Solutions
Spontaneous disengagement of 1. External levers and relay rods Adjust correctly. creeper unit. incorrectly adjusted. 2. Engagement stroke incom- Eliminate the cause and reset the plete. complete stroke. 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 Section 18.
4. Selector sleeve damaged.
Remove the clutch−gearbox casing and replace the sleeve.
5. Internal controls do not slide Overhaul the controls. easily: rods, forks and sleeves. Excessive noise in creeper.
87744428A − 11 − 2007
1. Internal components worn or Remove the clutch casing and redefective. place the damaged parts.
SECTION 21 − TRANSMISSIONS − CHAPTER 1
17
Op. 21 118 10 − 21 118 12 REAR TRANSMISSION−GEARBOX CASING Removal−Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that the units or parts are supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted.
Proceed as follows. 1. Carry out operation 90 110 50: Control panel, only removal (see Section 90, Chapter 1). 2. Carry out operation 90 114 26: Rear roll bar, only removal (see Section 90, Chapter 1). 3. Carry out operation 90 116 24: Rear guard, only removal (see Section 90, Chapter 1). 4. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see Section 23, Chapter 1). 5. Carry out operation 10 216 10 Fuel tank, only removal (see Section 10, Chapter 1). 6. Lock the front wheels using chocks. 7. Remove the top link of the third point. 8. Using a hoist and sling (1) raise the rear part of the tractor, position a fixed support stand under the towing hook, then remove the right−hand (2) and left hand wheels. 27837
14 9. Unscrew the plug and drain the oil from the rear transmission casing (the prescribed quantity is 11.09 US gal. (42 litres)).
25628
15
87744428A − 11 − 2007
18
SECTION 21 − TRANSMISSIONS − CHAPTER 1
10. Unscrew the stabiliser strut bracket retaining bolts (1).
27840
16 11. Attach tool 50091 (1) and adapter 50114 (2) to the lateral gear unit body.
27841
17 12. Position a hydraulic jack (2) under the gear unit, unscrew the retaining bolts and, using the jack (2), remove the right−hand gear unit (1) and the spacer. 13. Detach and remove the vertical rods, complete with the lower arms.
27842
18 14. Remove the pick−up bar, connect the pick−up hitch hook (2), using a chain (1), to the hoist, loosen the retaining bolts and detach the hook.
1
2
25627
19 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
15. Disconnect and remove the lift auxiliary control valve control pipes (1) and trailer brake control (2).
1
19
2
25449
20 16. Unscrew the retaining bolts and extract the Lift− O−Matic control lever (1).
1
25450
21 17. Unscrew the retaining bolts on the lift (1) and recover the trailer brake control pipes support bracket. Disconnect the power take−off speed sensor connections, if necessary.
1 25451
22 18. Attach the lifting hook 380000227 (1) to the lift (2) and, by means of the hoist, raise and remove the lift.
1
2
25452
23 87744428A − 11 − 2007
20
SECTION 21 − TRANSMISSIONS − CHAPTER 1
19. Unscrew and remove the filter pipes (2) and the transmission−gearbox casing pipes. 20. Disconnect the union (3) on the front differential lock control pipes and loosen the clamp.
27795
24 21. Unscrew the clamp (1) and detach the sleeve on the oil intake pipes, unscrew the union (2) and remove the lift oil feed pipes, detach and remove the two transmission gearbox casing pipes.
27796
25 22. Disconnect the brake control pipes (1) from the brake block and the rear transmission casing and remove. 23. Unscrew the union and the retaining bolt, then remove the pipes (2).
26 24. Disconnect the unions on the heat exchanger pipes (1).
1
25640
27 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
25. Disconnect the unions (2) and remove the pipes (1 and 3). 26. Unscrew the retaining bolts and remove the cab support bracket (on both sides).
1
21
2
3
25642
28 27. Position a fixed stand (1) under the engine.
1
27943
29 28. Screw on the four hooks (1) and, using a chain, connect them to a hoist, unscrew the retaining bolts that secure the clutch casing to the engine and detach the engine, together with the rear transmission.
1
27944
30 29. Position the rear transmission−clutch unit on a workbench. Unscrew the retaining bolts and recover the services control valve (1).
1
25654
31 87744428A − 11 − 2007
22
SECTION 21 − TRANSMISSIONS − CHAPTER 1
30. Extract the pin (3), detach the external lever (1), unscrew the retaining bolts and remove the support (2), complete with control lever.
2
1
3
25655
32 31. Remove: the parking brake control lever (5), the drive gear control oil union (4) and the electric sensors (1, 2 and 3).
1
3
2
4 5 25656
33 32. Position two nylon slings (1) under the clutch casing (2) and attach to the hoist. Unscrew the retaining bolts that secure the clutch casing to the transmission casing and remove. 33. To refit the rear transmission−gearbox casing, proceed as follows.
1
2
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 25657
−
−
− − −
For the correct orientation of the various parts, refer to the illustrations on pages 8, 9, 10, 11, 12, 13 and 14. Before refitting casings, supports and covers, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 0.0787 in. (2 mm) diameter as shown in the diagram on page 33. Respect the tightening torques prescribed on page 2. Re−fit the clutch casing on the rear transmission−gearbox case. Fit the electric sensors, the drive gear oil union and the parking brake control external lever.
87744428A − 11 − 2007
34
SECTION 21 − TRANSMISSIONS − CHAPTER 1 −
− − − − − − − − − − − − − − − − − − − −
− − − −
Fit the support complete with creeper−shuttle control lever, remembering to attach the lever (2) to the bracket (1) and to insert the unit positioned in an anticlockwise direction, then straighten−up the unit when it comes into contact with the casing, to facilitate the insertion of the lever (2) in the relative teeth. Assemble the creeper−reverser external control lever. Fit the services control valve. Refit the rear transmission−gearbox case and clutch casing to the engine. Attach the cab mounting. Connect all of the services control valve pipes. Connect the brake and services control pipes. Connect the heat exchanger pipes. Fit the rear transmission−gearbox case oil intake pipes. Connect the trailer brake and lift control pipes. Connect all of the lateral filter and front differential lock control pipes. Tighten the rear transmission−gearbox oil drainage plug. Assemble the hydraulic lift. Fit the Lift−O−Matic control lever. Assemble and connect the auxiliary control valve support and trailer brake valve pipes. Fit the hitch−hook and pick−up bar. Re−connect the vertical rods to the lift arms. Fit the brake disks, the differential axle shafts and side gears. Fit the rear wheels and remove the support stands. Carry out operation 10 216 10 Fuel tank, only installation (see Section 10, Chapter 1). Carry out operation 23 101 26 Transmission shafts and guard, only installation (see Section 23, Chapter 1). Carry out operation 90 116 24 Rear guard, only installation (see Section 90, Chapter 1). Carry out operation 90 114 26 Rear roll bar, only installation (see Section 90, Chapter 1). Carry out operation 90 110 50 Control panel, only installation (see Section 90, Chapter 1). Fill up the rear transmission−gearbox casing (see page 6, Section 00 for prescribed products and quantities).
23
1 2
27945
35
87744428A − 11 − 2007
24
SECTION 21 − TRANSMISSIONS − CHAPTER 1
Op. 21 118 85 GEARBOX TRANSMISSION CASING Disassembly− Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Fix the gearbox −transmission casing to the rotating stand 380000301 using brackets 50157 (see figs. 4 and 5). 2. Carry out operation 23 101 40 or 23 202 50 Drive gear casing assembly, only removal (see Section 23, Chapter 1). 3. Unscrew the retaining bolts and remove the cover (1) with the gearbox lever and gear unit. 4. Detach the power take−off control shaft following the instructions in Section 31.
25717
36 5. Remove the parking brake casing cover and extract the circlip (1) that secures the parking brake control lever.
25718
37 6. Extract the parking brake control lever (2) and recover the sleeve−cam (1).
25721
38
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
25
7. Loosen the retaining bolt and remove the cover (1).
25734
39 8. Remove the circlip (2) and recover the unit (1) composed of the brake disk and the relative friction sectors.
25735
40 9. Fit tool 380001615 (1) on the driving shaft and lock in position, insert tool 380001616 (2) on the gearbox driven shaft and tighten.
NOTE: If the gearbox in question is a standard fitting, fit a M 12 x 1.25 x 40 screw together with a ∅ 12 x ∅ 45 washer and 0.1181 in. (3 mm) shim, instead of tool 380001616 (2).
25736
41 10. Remove the circlip from the front side of the casing and, using an extracting tool, extract the final drive driven shaft and recover the driven gears (1).
25737
42
87744428A − 11 − 2007
26
SECTION 21 − TRANSMISSIONS − CHAPTER 1
11. Extract the lubrication pipe (1) from the gearbox.
25738
43 12. Remove the circlip (1) and the union (2), complete with the lubrication pressure adjustment valve.
25739
44 13. Unscrew the lubrication union (1) from the left− hand side of the casing.
25740
45 14. Remove the union (2) and the lubrication sleeve (1).
25741
46 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
27
15. Enlarge the circlip (1) that secures the gearbox driving shaft.
25742
47 16. From the drive gear case, enlarge the circlip (1) that secures the gearbox driven shaft.
25744
48 17. Unscrew the gearbox retaining bolts (1) and remove, using a hoist.
25743
49 18. Fit tool 380001614 (2) in a vice and remove the mobile part (1) of the tool.
25774
50
87744428A − 11 − 2007
28
SECTION 21 − TRANSMISSIONS − CHAPTER 1
19. Fit the gearbox unit to the tool 294074 (1) and re− fit the mobile part (2) of the tool.
25775
51 20. Remove the pins (1) to free the gearbox control forks (on one side).
25776
52 21. Extract the pins (1) on the other side of the gearbox and remove: the upper part (1) of tool 380001614, tool 380001615 (2) from the driving shaft and retaining tool 380001616 from the driven shaft.
25777
53 22. Remove the driving (1) and driven (2) shafts.
25778
54 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
29
23. From the opposite side, remove the rod stop ring (2), extract and recover the reverser control fork (1).
25779
55 24. Extract the circlip (1) and recover the synchroniser (2).
25780
56 25. Unscrew the retaining bolt (2) and recover the pin (3), relay gear (1) and relative bearings and thrust washers.
25781
57 26. Enlarge the circlip (3) that secures the driven gear (1) to the gearbox support (2) and remove the gear (1).
25782
58
87744428A − 11 − 2007
30
SECTION 21 − TRANSMISSIONS − CHAPTER 1
27. Enlarge the circlip (1) and extract the gearbox driven shaft (2). 28. To re−fit the transmission−gearbox casing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
25783
59 −
For the correct orientation of the various parts, refer to the illustrations on pages 8, 9, 10, 11, 12, 13 and 14.
−
Before refitting casings, supports and covers, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 0.0787 in. (2 mm) diameter as shown in the diagram on page 33.
−
Respect the tightening torques prescribed on page 2.
−
Carry out the gearbox driven and driving shaft adjustments noted on page 32.
−
Fit the gearbox driving shaft on the relative support.
−
Fit the gearbox driven gear on the relative support.
−
Fit the reverse drive gear complete with thrust washer, bearing and retaining bolt.
−
Assemble the synchroniser and circlip.
−
Fit the reverser control rod, fork and stop circlip.
−
Assemble the driven and driving shafts, the control forks and lock in position by means of tools 380001616 and 380001615, fit the mobile part of tool 380001614.
−
Fit the control forks to the rods using the pins.
−
Detach the mobile part of the tool 380001614 and remove the gearbox unit from the tool.
−
Fit tools 380001618 and 380001619 (1) on the driving shaft lock circlip and the driven shaft lock circlip respectively.
25784
60
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1 −
Using a hoist, fit the gearbox unit in the casing and recover the tools 380001618 (1) and 380001619 (the latter must be recovered from the drive gear casing). Secure in position with the bolts.
−
Fit the lubrication union and sleeve.
−
Fit the lubrication pressure adjustment valve, complete with the union and circlip.
−
Assemble the lubrication pipes.
31
25785
−
Fit the driven shaft and gears.
−
Remove tools 380001615 and 380001616 from the driving and driven shafts respectively.
−
Fit the parking brake unit, comprising brake disks and friction sectors.
−
Fit the cover (1) and secure with the bolt (2).
61
NOTE: Apply Loctite 242 thread locker to the thread on bolt (2) and tighten to a torque setting of 19.6 Nm (2 kgm).
−
Assemble the parking brake control lever, complete with cam sleeve and circlip.
−
Fit the parking brake cover. 25786
−
Assemble the power take−off control shaft, following the instructions in Section 31.
−
Fit the cover with the gearbox control lever and final drive.
−
Carry out operation 23 101 40 or 23 202 50 Drive gear casing assembly, only removal (see Section 23, Chapter 1).
−
Detach the transmission−gearbox casing from the rotating stand.
62
87744428A − 11 − 2007
32
SECTION 21 − TRANSMISSIONS − CHAPTER 1
TRANSMISSION−GEARBOX CASING Gearbox driving and driven shafts clearance adjustment.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. Proceed as follows. NOTE: When fitted, the driving and driven shaft gears must provide an axial clearance of 0.0314 in. (0.8 mm) in order to guarantee correct synchronizer operation.
25787
63
29. Using tool 380001614 (1) clamped in the vice, attach the gearbox support complete with the driving and driven shafts without the respective adjustment shims (4 and 12, page 8), fit the mobile part (2) on the tool. 30. Using a depth gauge, measure the distance (L) between the top of the tool 380001614 (1) and the circlip (3) on the driving shaft bearing. 31. Measure the distance (L1) between the top of the tool 380001614 (1) and the circlip (2) on the driving shaft bearing. 32. The adjustment shim (4, page 8) to fit on the driving shaft is given by: S = L − 46.5 − 1.0 where L = measurement read 46.5 = theoretical measurement of tool 380001614 1.0 = synchronizer operating clearance. Round down the value. 33. The adjustment shim (12, page 8) to fit on the driven shaft is given by: S1 = L1 − 36 − 1.0 L1 = measurement read 36 = theoretical measurement of tool 380001614 1.0 = synchronizer operating clearance. Round down the value Example: L = 1.9212 in. (48.8 mm). Measurement read L1 = 1.4881 in. (37.8 mm). Measurement read 46.5 = Theoretical measurement of tool 380001614 36 = Theoretical measurement of tool 380001614 1.0 = synchronizers operating clearance. S = 1.9212 − 1.8307 − 0.0393 = 0.0511 in. (48.8 − 46.5 − 1.0 = 1.3 mm) (adjustment shim 4, page 6). S1 = 1.4881 − 1.4173 − 0.0393 = 0.0314 in. (37.8 − 36 − 1.0 = 0.8 mm) (adjustment shim 12, page 6). The adjustment shims are listed on page 2. Round down the value.
87744428A − 11 − 2007
25788
−
64 Using a hoist, fit the gearbox unit in the casing and recover the tools 380001618 (1) and 380001619 (the latter must be recovered from the drive gear casing). Secure in position with the bolts.
−
Fit the lubrication union and sleeve.
−
Fit the lubrication pressure adjustment valve, complete with the union and circlip.
−
Assemble the lubrication pipes.
−
Fit the driven shaft and gears.
SECTION 21 − TRANSMISSIONS − CHAPTER 1
33
27152
65 Sealing compound application diagram for transmission−gear box casing The types of sealing compound are listed on page 1, Section 00.
87744428A − 11 − 2007
34
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 1
SECTION 21 − TRANSMISSIONS − CHAPTER 2
1
SECTION 21 − TRANSMISSIONS Chapter 2 − Power Shuttle Transmission (16 + 16) CONTENTS Section
Description
Page
21 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
21 118 85
Gearbox transmission casing. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
21 134 46
Power shuttle control valve. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
21 134 62
Accumulator. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
21 134 70
Gearbox control valve solenoid valve. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . 21
21 154 34
Clutch casing. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
21 154 60
Clutch casing. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Error codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
TRANSMISSION AND RANGE GEAR DATA Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4 speed, constant−mesh, with synchronisers on all gears
Gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
helical
Range gear (16 + 16 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 4 ranges for a total of 16 speeds
Range gear (8 + 8 version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ordinary gear train with 2 ranges for a total of 8 gears
−
gearing type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Gearbox and range gear operating system . . . . . . . . . . . . . . . . . . .
spur independent, by means of lever located on right−hand side of operator
For missing data see Chapter 1, page 2.
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2
SECTION 21 − TRANSMISSIONS − CHAPTER 2 POWER SHUTTLE MAIN DATA
Number of driven plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
6
Thickness of driven plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0787 to 0.0818 (2.00 to 2.08)
Driven plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
sintered
Number of driving plates in each clutch . . . . . . . . . . . . . . . . . . . . . .
no.
6
Thickness of driving plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0787 to 0.0866 (2.00 − 2.20)
Driving plate material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of clutch assembly under a load of 1600 N (359.73 lbs. (163.1 kg)) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steel in. (mm)
0.9803 to 0.9881 (24.9 to 25.1) (1)
Clutch piston return spring (4, pages 7 and 8): −
number of springs for each clutch . . . . . . . . . . . . . . . . . . . . . . .
no.
7
−
spring free height . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.1299 (3.30)
−
spring height under a load of 1255 N (282.31 lbs. (128 kg)) .
in. (mm)
0.1031 (2.62)
Hydraulic control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Power Shuttle and services transmission working pressure . . . . .
mounted on the outer left−hand side of the transmission−rear−gearbox casing, comprising no. 3 control solenoid valves. psi (bar)
227.65 (15.7)
in. (mm)
4.8031 (122)
in. (mm)
3.937 (100)
in. (mm)
1.3976 (35.5)
in. (mm)
1.0039 (25.5)
Accumulator spring (3, page 11) accumulator: −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
length of spring under load of 325 to 359 N (73.22 to 80.72 lbs. (33.2 to 36.6 kg)) . . . . . . . . . . . . . . . . . . . .
By−pass valve spring (6, page 11): −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
length of spring under load of 37.2 to 41.2 N (8.38 to 9.26 lbs. (3.8 to 4.2 kg)) . . . . . . . . . . . . . . . . . . . . . . . .
Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
fixed to the pump housing on suction side
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
the same as used for the hydrostatic steering system (see Section 41, Chapter 2)
(1) Value to obtain by varying the thickness of the driving plates.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
3
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
For missing data see Chapter 1, page 2. Solenoid valve retaining nut (C1) (•) . . . . . . . . . . . . . . . . . . . . . . .
−
1.7 to 2.8
0.17 to 0.28
Solenoid valve spool retaining bolt (C2) . . . . . . . . . . . . . . . . . . . .
−
14.9 to 20.3
1.52 to 2.07
Solenoid valve spool retaining bolts (C3) . . . . . . . . . . . . . . . . . . .
−
47 to 54
4.8 to 5.5
Solenoid valve retaining nut (C4) (•) . . . . . . . . . . . . . . . . . . . . . . .
−
5.4 to 8.1
0.55 to 0.83
(•) Apply 1 or 2 drops of LOCTITE 542 before tightening
27951A
C4−5.4 ÷ 8.1 Nm
C3−47 ÷ 54 Nm
25792
1
87744428A − 11 − 2007
4
SECTION 21 − TRANSMISSIONS − CHAPTER 2
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 380000301 X 380001614
Clutch casing lift hook. Rotating stand for overhaul operations. Tool for gearbox driving and driven shafts adjustment.
X 380001621 X 380001616 X 380001610 X 380001620 X 380001609
X X X X X
380001617 380001618 380001619 380000171 380000291
X 380000240
Driving shaft rod for lifting unit. Driven shaft retaining tool. Adjuster handle (with 380001620 and 380001609). Power take−off drive shaft seal splining tool (with 380001610). Power take−off drive shaft roller bearings splining tool (with 380001610). Pliers for gearbox shafts circlips. Driving shaft assembly guide. Driven shaft fitting guide. Adaptor (with 380000291). Tool for hydraulic clutch piston springs (with 380000171). Hydraulic pressure testing kit.
24663
2 Tool to be made for disassembly−assembly of the final drives, to be used with 50114. (Mark part with No. 50091 − Measurements in mm) 1. Make 2 tie−rods in C 40 bon material. − Make in Aq 42 D material.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
5
26258
3 Tool to be made for lateral gear removal−installation, use with a part of 50091. (Mark part with No. 50114 − Measurements in mm) Make in Fe 42 C material − (*) Measurement according to hoist seat.
87744428A − 11 − 2007
6
SECTION 21 − TRANSMISSIONS − CHAPTER 2
27941
4 Bracket to be made for gearbox overhaul on rotating stand. (Mark tool No. 50157 − Measurements in mm). Make in Aq 42 material.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
7
(1)
27940
5 Bracket to be made for gearbox overhaul on rotating stand. (Mark tool No. 50157 − Measurements in mm) 1. Rotating stand shaft − Make in Aq 42 material.
87744428A − 11 − 2007
8
SECTION 21 − TRANSMISSIONS − CHAPTER 2
25618
6 Guide pin for re−fitting the gearbox in the casing. (Mark part with no. 50158 − Measurements in mm) Make in C 40 material.
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
9
7 Longitudinal cross−sectional view of Power Shuttle gearbox (16 + 16 version) 1. 2. 3. 4. 5. 6.
Forward gear control clutch piston. Forward gear control clutch. Piston return Belleville washer. Reverse gear control clutch. Reverse gear control clutch piston. Forward gear drive shaft.
7. 8. 9. 10. 11.
Reverse drive shaft. Reverse driven shaft. Reverse gear clutch control piping. Forward gear clutch control piping. Lubrication control pipes.
NOTE: For views and missing data see Chapter 1.
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10
SECTION 21 − TRANSMISSIONS − CHAPTER 2
8 Cross−sectional views of Power Shuttle gearbox 1. 2. 3. 4.
Power Shuttle control valve. Gear control internal rods. Gear control external lever. Pin.
87744428A − 11 − 2007
5. 6. 7.
Pin retaining bolt (4). Reverse intermediate gear. Needle bearing.
SECTION 21 − TRANSMISSIONS − CHAPTER 2
11
9 Longitudinal cross−sectional view of Power Shuttle gearbox (8 + 8 version) 1. 2.
Low gear intermediate gear. Selector sleeve for high gears.
3. 4.
Selector sleeve for low gears. Bevel pinion.
NOTE: For missing data see page 9 and Chapter 1.
87744428A − 11 − 2007
12
SECTION 21 − TRANSMISSIONS − CHAPTER 2
5 4
MDE0067A
10 Power Shuttle control valve. 1. 2. 3.
Reverse clutch control solenoid valve. Forward clutch control solenoid valve. Dump solenoid valve.
4. 5.
Reverse gears clutch working pressure control plug. Forward gears clutch working pressure control plug.
CLUTCH CONTROL PRESSURE TEST Unscrew plug (4) or (5) on the clutch to be tested and connect a pressure gauge from kit 380000240 to the relative hole. Start the engine and check the pressure (see page 2).
87744428A − 11 − 2007
If the pressure is incorrect adjust the shims (3, fig. 11), increase if the pressure is low and decrease if too high.
SECTION 21 − TRANSMISSIONS − CHAPTER 2
2
1
13
3
4
6
27804A
5
11 Cross−sectional view of services control valve 1. 2. 3.
Four wheel drive release solenoid valve. Spring for services control oil pressure adjustment valve. Services control oil pressure adjustment shims.
1
2
4. 5. 6.
By−pass valve spring. By−pass valve. Services control pressure adjustment valve.
3
27085
12 Cross−sectional view of accumulator 1. 2.
Ball valve. Accumulator piston.
3.
Accumulator spring.
87744428A − 11 − 2007
14
SECTION 21 − TRANSMISSIONS − CHAPTER 2 DESCRIPTION AND OPERATION
Gearbox 4−speed gearbox with constant−mesh helical gears controlled by two synchronizers. The range gear has cascade−type constant−mesh spur gears. The range gear provides 2 gear ranges (8 + 8 version) or 4 gear ranges (16 + 16 version). The gearbox and the range gears are controlled by two independent levers located on the right−hand side of the operator. Gear reversal is obtained by means of the lever (1) 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. Lubrication is by means of the oil in the rear transmission casing/gearbox.
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 controls the forward gears, the rear clutch controls the reverse gears.
GEARBOX AND GEAR RANGE TROUBLESHOOTING See Chapter 1, pages 15 and 16.
87744428A − 11 − 2007
47a
SECTION 21 − TRANSMISSIONS − CHAPTER 2
15
Op. 21 118 85 GEARBOX TRANSMISSION CASING Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Carry out operation 21 118 12 Rear transmission−gearbox casing, only removal (see Chapter 1). 2. Disconnect the pipes (2) on the accumulator (1), unscrew the retaining bolts and remove the accumulator.
27086
13 3. Unscrew the retaining bolts and recover the services control valve (1).
1
25654
14 4. Unscrew the retaining bolts and detach the Power Shuttle (1) control valve. 5. Attach the transmission−gearbox casing on the rotating stand 380000301 using brackets 50160 (see pages 5 and 6).
27087
15
87744428A − 11 − 2007
16
SECTION 21 − TRANSMISSIONS − CHAPTER 2
6. Unscrew the retaining bolts (1) on the clutch control pipes (2).
27088
16 7. Rotate and remove the clutch control pipes (1).
27089
17 8. Unscrew the unions (1 and 2) on the clutch control pipes and recover the internal unions.
27090
18 9. Loosen the shuttle control pin (1). 10. Complete the gearbox removal operations by following the instructions in Chapter 1, page 24. 11. To refit the unit, carry out the disassembly operations in reverse order, following the instructions in Chapter 1.
27091
19 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
17
Op. 21 134 46 POWER SHUTTLE CONTROL VALVE Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
With the Power Shuttle control valve on the workbench, proceed as follows. 1. Extract the pin (1) that retains the creeper unit control lever (2). 27109
20 2. Extract the creeper unit control lever (1) and recover the internal lever (2).
27110
21 3. Unscrew the nut (1) and extract the solenoid valve (2).
27111
22
87744428A − 11 − 2007
18
SECTION 21 − TRANSMISSIONS − CHAPTER 2
4. Unscrew the solenoid valve pin (1). 5. Carry out operations no. 3 and 4 also for the solenoid valve (2).
27112
23 6. Unscrew the nut (2) and extract the solenoid valve (1).
27113
24 7. Unscrew the solenoid valve pin (1). 8. Carry out operations no. 6 and 7 also for solenoid valves (2 and 3).
27114
25 9. Remove the circlip (1).
27115
26 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
19
10. Remove the plug (1) and recover the shuttle control pin (2).
27116
27 11. Remove the switch (1). 12. To refit the Power Shuttle control valve, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
For the correct orientation of the various parts, refer to the illustrations on page 10.
−
Respect the tightening torques prescribed on page 3.
−
Fit the switch.
−
Assemble the control pin, plug and circlip.
−
Fit the pins and relative solenoid valves then, after having applied 1 or 2 drops of Loctite 542, tighten the nuts.
−
Assemble the internal lever, the creeper unit control lever and the pin.
27117
28
87744428A − 11 − 2007
20
SECTION 21 − TRANSMISSIONS − CHAPTER 2
Op. 21 134 62 ACCUMULATOR Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
With the accumulator on the workbench, proceed as follows. 1. Unscrew the cap (1) and recover the spring (2, fig. 30) and piston (3, fig. 30).
27118
29 2. Accumulator parts: cap (1), spring (2), piston (3) and accumulator body (4). 3. To re−fit the accumulator, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
For the correct orientation of the various parts, refer to the illustrations on page 10.
−
Insert the piston and spring in the accumulator body.
−
Tighten the cap.
87744428A − 11 − 2007
27119
30
SECTION 21 − TRANSMISSIONS − CHAPTER 2
21
Op. 21 134 70 GEARBOX CONTROL VALVE SOLENOID VALVE Removal − Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
In order to remove a control solenoid valve from the two clutches, the working area must be kept clean. Proceed as follows. 1. Carry out operation 10 216 10 Fuel tank, only removal (see Section 10, Chapter 1). 2. Disconnect the solenoid valve connection (1).
31 3. Loosen the nut and remove the solenoid valve (1).
32 4. Unscrew the solenoid valve pin (1). 5. To refit the control valve solenoid, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Screw the pin on the solenoid valve.
−
Fit and secure the solenoid valve.
−
Connect the electrical connection.
−
Carry out operation 10 216 10 Fuel tank, only installation (see Section 10, Chapter 1).
33
87744428A − 11 − 2007
22
SECTION 21 − TRANSMISSIONS − CHAPTER 2
Op. 21 134 70 GEARBOX CONTROL VALVE SOLENOID VALVE Removal − Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
In order to remove a control solenoid valve from the gearbox, the working area must be kept clean. Proceed as follows. 1. Carry out operation 10 216 10 Fuel tank, only removal (see Section 10, Chapter 1). 2. Disconnect the solenoid valve connection (1) and unscrew the retaining nut. 34 3. Remove the solenoid valve (1).
35 4. Unscrew the solenoid valve pin (1). 5. To refit the control valve solenoid, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Screw the pin on the solenoid valve.
−
Fit and secure the solenoid valve.
−
Connect the electrical connection.
−
Carry out operation 10 216 10 Fuel tank, only installation (see Section 10, Chapter 1).
87744428A − 11 − 2007
36
SECTION 21 − TRANSMISSIONS − CHAPTER 2
23
Op. 21 154 34 − 21 154 60 CLUTCH CASING Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Carry out operation 21 118 12 Rear transmission−gearbox casing, only removal (see Chapter 1). 2. Attach the clutch casing to the rotating stand 380000301 using brackets 50157 (see figs. 4 and 5). 3. Unscrew the retaining bolts and remove the clutch control pipes (1). 27092
37 4. Unscrew the retaining bolt and recover the sleeve (1), fork (2) lever (3) and spring (4).
27093
38 5. Unscrew the rear bearing support retaining bolts (1).
27094
39
87744428A − 11 − 2007
24
SECTION 21 − TRANSMISSIONS − CHAPTER 2
6. Unscrew the front bearing support (2) retaining bolts (1).
27095
40 7. Insert tool 380001621 (1) on the clutch unit (2), secure in position and remove, using a hoist.
27096
41 8. Position the clutch unit (1) on a workbench, remove tool 380001621 (2) and separate the unit into two parts.
27097
42 9. Unscrew the retaining bolts and remove the sleeve (1) for the power take−off clutch engagement sleeve.
27098
43 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
25
10. Remove the circlip (1) and remove the front bearing support (2).
27100
44 11. Remove the circlip (1) and remove the shaft (2).
27101
45 12. Remove the circlip (1) that secures the clutch disk assembly.
27102
46 13. Extract the gear (1) and recover the clutch disk assembly (2) and the relative clips (3).
27103
47
87744428A − 11 − 2007
26
SECTION 21 − TRANSMISSIONS − CHAPTER 2
14. Using an extractor (1) and tool 380000291 (2) compress the Belleville washer (3), remove the stop ring (4) and recover the above−mentioned springs and piston.
27104
48 15. Remove the stop ring (1) and extract the clutch body (2).
27105
49 16. Remove the front bearing support (1).
271106
50 17. Remove the circlip (1) and remove the bearing (2). 18. To refit the clutch casing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. − −
For the correct orientation of the various parts, refer to the illustrations on pages 9, 10 and 11. Respect the tightening torques prescribed on page 3.
27107
51 87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
27
−
Assemble the front bearing and circlip on the shaft.
−
Unite the two clutch units and lock in position by means of tool 380001621.
−
Fit the front bearing support.
−
Insert the clutch unit in the casing.
−
Insert the clutch body and stop ring.
−
Fit the front bearing support by means of the bolts.
−
Insert the piston and fit the Belleville washer and circlip.
−
Fit the rear bearing support by means of the bolts.
Assemble the clutch disk assembly complete with springs and gear.
−
Assemble the lever, spring, fork and the power take−off clutch engagement sleeve.
Assemble the other clutch, as described previously.
−
Fit the clutch control pipes.
−
Fit the shaft and stop ring.
−
Detach the casing from the rotating stand.
−
Assemble the front bearing support and circlip.
−
−
Fit the sleeve for the power take−off clutch engagement sleeve.
Carry out operation 21 118 12 Rear transmission−gearbox casing, only installation (see Chapter 1).
−
−
87744428A − 11 − 2007
28
87744428A − 11 − 2007
SECTION 21 − TRANSMISSIONS − CHAPTER 2
SECTION 23 − DRIVE LINES − CHAPTER 1
1
SECTION 23 − DRIVE LINES Chapter 1 − Drive lines CONTENTS Section
Description
Page
23 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description, operation and hydraulic diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
23 101 26
Propeller shafts and guard. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
23 101 40
Drive gear assembly. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
23 202 50
Drive gear assembly. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
23 101 42
Drive gear housing removed. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
23 202 52
Drive gear housing removed. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
MAIN SPECIFICATIONS − 4WD ELECTROHYDRAULIC ENGAGEMENT Reduction ratio of drive gear device (on all models) . . . . .
43/28X28/39 = 1:1.1
Internal diameter of sliding sleeve (16, fig. 4) . . . . . . . . . . .
in. (mm)
1.3810 to 1.3826 (35.080 to 35.119)
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.3769 to 1.3779 (34.975 to 35.000)
Internal diameter of sliding sleeve (16) . . . . . . . . . . . . . . . .
in. (mm)
1.9716 to 1.9731 (50.080 to 50.119)
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.9281 to 1.9645 (48.975 to 49.900)
Internal diameter of fixed sleeve (15) . . . . . . . . . . . . . . . . . .
in. (mm)
0.8686 to 0.8699 (22.065 to 22.098)
Diameter of coupled shaft (1) . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.8653 to 0.8661 (21.979 to 22.000)
Length of spring (20, with spring free) . . . . . . . . . . . . . . . . .
in. (mm)
3.2283 (82)
Length of spring (20) under a load of 133.44 to 144.46 lbs. (60.5 to 65.5 kg) . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.5748 (40)
PROPELLER SHAFT DATA Thickness of rings (2, fig. 5) that adjust the position of the front sleeve (3) on the 4WD propeller shaft . . . . . . . . . . . .
in. (mm)
0.0590 − 0.0748 − 0.0866 − 0.0984 − 0.1102 − 0.1181 − 0.1299 − 0.1456 − 0.1574 − 0.1692 (1.5 − 1.9 − 2.2 − 2.5 − 2.8 − 3 − 3.3 − 3.7 − 4 − 4.3)
Front sleeve axial clearance (L) . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0393 to 0.0590 (1.0 to 1.5)
87744428A − 11 − 2007
2
SECTION 23 − DRIVE LINES − CHAPTER 1 TIGHTENING TORQUES
C1−88Nm
27836
C2 − 98 Nm
C3 − 49 Nm 25976
1 PARTS TO BE TIGHTENED
Thread
Propeller shaft central support retaining bolt (C1) . . . . . . . . . . . . .
Tightening torque Nm
kgm
M 12 x 1.5
88
9
Drive gear housing retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
98
10
Control cylinder oil delivery union (C3) . . . . . . . . . . . . . . . . . . . . . . .
M 18 x 1.50
49
5
87744428A − 11 − 2007
SECTION 23 − DRIVE LINES − CHAPTER 1
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.
List of specific tools required for the various operations described in this Section. X 380001622
Drive shaft seal key.
X 380000279
Key for 1.9685 in. (Ø 50 mm) piston.
X 380000280
Key for 1.3779 in. (Ø 35 mm) piston.
X 380000240
Hydraulic pressure control kit (use tool 380000560).
27827
2 Tool to make for drive gear unit removal (stamp no. 50161 on the tool − Measurements in mm) Make in Fe 42C material.
87744428A − 11 − 2007
4
SECTION 23 − DRIVE LINES − CHAPTER 1
27828
3 Tool to make for drive gear shaft removal (stamp no. 50141 on the tool − Measurements in mm) Make using C40 material. Spring pin 0.1181 x 0.7874 in. (3 x 20 mm).
87744428A − 11 − 2007
SECTION 23 − DRIVE LINES − CHAPTER 1
1
3 4
2
5 6 7 8
9 10 11
5
12 13 14 15 16 17 18 19
27
20
26
25
24
27829
22 23 27831
27830
21 4
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.
Driven shaft. Dust ring. Seal. Circlip. Bearing. Circlip. Metal seal segment. Metal seal segment. Circlip. Bearing. Driving gear. Gear sleeve. Seal. Metal seal segments.
Sectional view of drive gear with electrohydraulic coupling 15. Seals. 16. Mobile coupling. 17. Circlip. 18. Flexible pin. 19. Plate. 20. 4WD engagement spring. 21. Rear axle speed sensor. 22. Transmission oil drainage plug. 23. Front axle speed sensor. 24. Thrust ring. 25. Manifold ring. 26. Circlip. 27. Circlip.
NOTE: On installation, apply sealing compound to the surfaces X (See Section 27, Chapter 1). 87744428A − 11 − 2007
6
SECTION 23 − DRIVE LINES − CHAPTER 1
20
L
4
3
2
1
25978
5 Control cylinder oil delivery union and front grooved sleeve L. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
Axial clearance of sleeve (3). Circlip. Adjustment shim. Sleeve. Circlip. Flat washer. Bolt. Plug. Flat seal. Fitting. Flat seal.
87744428A − 11 − 2007
11. 12. 13. 14. 15. 16. 17. 18. 19. 20.
Fitting. Seal. ‘O’ ring seal. Rigid piping. ‘O’ ring seal. Manifold ring. ‘O’ ring seal. Rigid piping. ‘O’ ring seal. Drive gear housing.
SECTION 23 − DRIVE LINES − CHAPTER 1
1
2
3 4
5
7
6
8
7
9 10 11 12 13
14
27832
10
13
15 16 17 18
27833
6 Sectional view of drive gear with mechanical coupling 1. 2. 3. 4. 5. 6. 7. 8. 9.
Driven shaft. Dust ring. Seal. Circlip. Bearing. Circlip. Circlip. Thrust ring. Bearing.
10. 11. 12. 13. 14. 15. 16. 17. 18.
Driving gear. Thrust ring. Circlip. Coupling sleeve. Transmission oil drainage plug. Control pad. Seal. External control lever. Lever return spring (17).
NOTE: On installation, apply sealing compound to the surfaces X (See Section 27, Chapter 1).
87744428A − 11 − 2007
8
SECTION 23 − DRIVE LINES − CHAPTER 1
25979
4WD gear engaged
4WD gear disengaged Circuit oil under pressure Circuit oil discharging
7
DESCRIPTION AND OPERATION OF THE 4WD DRIVE GEAR WITH ELECTROHYDRAULIC COUPLING The electrohydraulically operated 4WD is engaged by pressing the switch on the control panel. 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.
87744428A − 11 − 2007
The 4WD is disengaged by turning off the switch on the control panel. 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.
SECTION 23 − DRIVE LINES − CHAPTER 1
9
DESCRIPTION AND OPERATION The drive gear housing is mounted below the rear transmission gearbox and is driven by the transmission shaft via gear unit (11, fig. 4). Drive is then transmitted from the shaft (1) 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 on the control panel. A light on the control panel illuminates when the drive gear is engaged.
ELECTROHYDRAULIC DRIVE GEAR TROUBLESHOOTING Problems 4WD does not engage.
Possible Causes
Solutions
1. Drive gear engage/disengage Replace the 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. 4. Spring (20, page 4) stretched.
4WD remains engaged.
Overhaul the unit.
1. Transmission oil level insuffi- Top up oil level. cient. 2. Clogged oil filter.
Replace filter.
3. Hydraulic pump faulty.
Overhaul or replace pump.
4. Drive gear engage/disengage Replace the switch. switch faulty. 5. No power at solenoid valve: Check electrical connections and connections loose or damaged, 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 all defective 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.
1. Brake pump pressure switch Replace the pressure switch. faulty.
87744428A − 11 − 2007
10
SECTION 23 − DRIVE LINES − CHAPTER 1
Op. 23 101 26 PROPELLER SHAFTS AND GUARD Disassembly − Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
To remove, proceed as follows. 1. Unscrew the front, central and rear retaining bolts and remove the propeller shafts guard (1).
27801
8 2. Extract the rear circlip and unscrew the sleeve (1) back on the splined shaft. 3. Unscrew the central support bolts and extract the propeller shaft. 4. To re−fit the propeller shaft and relative guard, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
27802
9 −
Fit and secure the propeller shaft in position.
−
Fit and secure the guard.
87744428A − 11 − 2007
SECTION 23 − DRIVE LINES − CHAPTER 1
11
Op. 23 101 40 − 23 202 50 DRIVE GEAR HOUSING ASSEMBLY Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
1. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see page 10). 2. Remove the drainage plug and collect the oil in a suitable container. 25628
10 3. Remove the sensors (1) guard cover on the drive gear housing (electrohydraulic drive gear).
25980
11 4. Unscrew the retaining bolts (1) on the sensors (2) and remove from the drive gear housing (electrohydraulic drive gear). 5. Detach the drive gear engagement control lever (mechanical drive gear).
25981
12
87744428A − 11 − 2007
12
SECTION 23 − DRIVE LINES − CHAPTER 1
6. Unscrew the eight drive gear housing retaining bolts (1) on the transmission gearbox.
25982
13 7. Remove the drive gear housing (1) from the transmission gearbox. 8. To re−fit the drive gear housing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Respect the tightening torques prescribed on page 2.
−
Carefully clean the contact surfaces.
−
Apply the sealing compound (approx. 0.0787 in. (2 mm) in thickness), as shown in Section 27, Chapter 1.
−
Fit the drive gear housing on the transmission gearbox.
−
Re−fit the two speed sensors, securing in position with the two retaining bolts (electrohydraulic drive gear).
−
Connect the drive gear engagement control lever (mechanical drive gear).
−
Refit the transmission oil drainage plug.
−
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 10).
−
Refill the rear transmission gearbox (for products and quantities, see Section 00, page 6).
87744428A − 11 − 2007
25983
14
SECTION 23 − DRIVE LINES − CHAPTER 1
13
Op. 23 101 42 DRIVE GEAR HOUSING REMOVED Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see page 10). 2. Carry out operation 23 101 40 Drive gear housing assembly, only removal (see page 11). 3. Remove the dust ring (1) and seal (2).
25984
15 4. Remove the circlips and ball bearings (1) from the seating.
25985
16 5. Remove the circlip (5) and washer (4), extract the pin (3) and remove: the external lever (6), the internal lever (2) and the coupling pad (1).
1 2 6
27834
3 4 5 17
87744428A − 11 − 2007
14
SECTION 23 − DRIVE LINES − CHAPTER 1
6. Extract the coupling sleeve (1), remove the circlip (3) and remove: the washer (4), the gear unit (5) and the shaft (2).
1 2
7. To refit the drive gear housing, proceed as follows.
3 CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
4 27835
−
Insert the shaft in the housing, then assemble the gear unit, washer and circlip.
−
Fit the internal lever, the external lever, the coupling pad and secure in position by means of the washer and relative circlip.
−
Fit the bearing and relative circlips.
−
Use tool 380001622 to fit the seal and dust ring (use the spacer to fit the dust ring).
−
Carry out operation 23 101 40 Drive gear housing, only installation (see page 11).
−
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 10).
5 18
25989
19
87744428A − 11 − 2007
SECTION 23 − DRIVE LINES − CHAPTER 1
15
Op. 23 202 52 DRIVE GEAR HOUSING REMOVED Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Carry out operation 23 101 26 Propeller shafts and guard, only removal (see page 10). 2. Carry out operation 23 202 50 Drive gear housing assembly, only removal (see page 11). 3. Remove the dust ring (1) and seal (2).
25984
20 4. Remove the circlips and ball bearings (1) from the seating.
25985
21 5. Remove the pin (1) fitted on the opposite end of the shaft and slide off the oil delivery union.
25986
22
87744428A − 11 − 2007
16
SECTION 23 − DRIVE LINES − CHAPTER 1
6. Using tool 50141 (see fig. 3) and an extracting tool applied to the end of the shaft, remove the gears, the bearing, the 4WD coupling unit and the oil delivery manifold. 7. Using a hydraulic press and tool 50161 (see fig. 2), compress the spring and, by manipulating the washer, extract the retaining ring and remove the spring. Move the end of the piston (mobile coupling 16, fig. 4) to remove it from the housing.
25988
23 X−
8. To refit the drive gear housing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Check all parts and replace if worn.
−
Check the seals and the metal seal segments, replacing if necessary.
−
Lubricate all parts.
25989
NOTE: The seals (13 and 15, fig. 4) must be inserted in their respective housings as quickly as possible in order to avoid deformation, using (respectively) tools 380000279 and 380000280. −
Insert the piston in the seating.
−
Using a press and tool 50161 fit the spring, washer and retaining ring.
−
Fit the shaft, the oil delivery manifold, the 4WD coupling assembly and the bearing in the drive gear housing.
−
Fit the oil delivery union and secure the shaft by means of the circlip.
−
Fit the bearing and relative circlips.
−
Use tool 380001622 to fit the seal and dust ring (use the spacer to fit the dust ring).
−
Carry out operation 23 202 50 Drive gear housing, only installation (see page 11).
−
Carry out operation 23 101 26 Propeller shafts and guard, only installation (see page 10).
87744428A − 11 − 2007
24
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
1
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION Chapter 1 − Front axle mechanical transmission CONTENTS Section
Description
25 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross−sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Front axle. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Front axle. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Front axle differential. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Front epicyclic final gear with brake. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . 32 Front epicyclic final drive. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Steering knuckle bearing pins. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Front axle differential with LIM−SLIP. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Leading drive wheels toe−in check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
25 100 30 25 100 38 25 102 24 25 108 30 25 108 30 25 108 46 25 108 47 25 102 27 44 511 80
Page
DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
steering, load bearing structure, pivoting at centre
Bevel drive − differential Pinion−crown gear ratio 30 km/h: . . . . . . . . . . . . . . . . . . .
8/30= 1:3.75
Pinion−crown gear ratio 40 km/h: . . . . . . . . . . . . . . . . . . .
10/30= 1:3
Backlash between bevel drive teeth: . . . . . . . . .
mm
0,15 ÷ 0,20
Ratio between front wheel revs and rear wheel bevel drive revs 30 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1,378
Ratio between front wheel revs and rear wheel bevel drive revs 40 km/h: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1,374 (continued)
87744428A − 11 − 2007
2
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 DATA (cont)
0.0984 − 0.1023 − 0.1062 − 0.1102 − 0.1141 − 0.1181 − 122 − 0.1259 − 0.1299 − 0.1338 − 0.1377 − 0.1417 − 0.1456 (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) 0.0984 − 0.1003 − 0.1023 − 0.1043 − 0.1062 − 0.1082 − 0.1102 − 0.1122 − 0.1141 − 0.1161 − 0.1181 − 0.12 − 122 − 0.124 − 0.1259 − 0.1279 − 0.1299 − 0.1318 − 0.1338 − 0.1358 − 0.1377 − 0.1397 − 0.1417 − 0.1437 − 0.1456 − 0.1476 − 0.1496 − 0.1515 − 0.1535 − 0.1555 − 0.1574 − 0.1594 − 0.1614 − 0.1633 − 0.1653 − 0.1673 − 0.1692 − 0.1712 − 0.1732 − 0.1751 − 0.1771 − 0.1791 − 0.1811 − 0.183 − 0.185 − 0.187 − 0.1889 (2.5 − 2.55 − 2.6 − 2.65 − 2.7 − 2.75 − 2.8 − 2.85 − 2.9 − 2.95 − 3 − 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 − 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)
Thickness of bevel pinion position adjustment spacer rings (11, fig. 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
Thickness of pinion bearing adjustment spacer rings (12)
in. (mm)
Thickness of bevel crown wheel position adjustment spacer (4, fig. 5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
Clearance between sides of sun and planet pinion teeth . Thickness of planet pinion thrust washers . . . . . . . . . . . . . . Thickness of side gear thrust washers (1) . . . . . . . . . . . . . .
in. (mm) in. (mm) in. (mm)
Diameter of cross pin (14) for planet pinions . . . . . . . . . . . Side pinion cross pin bore diameter (3) . . . . . . . . . . . . . . . . Assembly clearance between cross pin and bores . . . . . . Axle shafts and steering knuckles Diameter of outer axle shafts (7, fig. 5) in correspondence with bushes (8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Inside diameter of installed bushes (8) . . . . . . . . . . . . . . . . Clearance between axle shafts and bushes . . . . . . . . . . . . Interference fit between bushes and respective bores . . . Thickness of steering knuckle bearing adjuster plates (10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm) in. (mm) in. (mm)
0.0354 − 0.0393 − 0.0433 − 0.0472 − 0.0511 − 0.0551 − 0.059 − 0.0629 − 0.0669 − 0.0708 − 0.0748 − 0.0787 (0.9 − 1 − 1.1 − 1.2 − 1.3 − 1.4 − 1.5 − 1.6 − 1.7 − 1.8 − 1.9 − 2) 0.0059 (0.15) 0.0578 to 0.0602 (1.47 to 1.53) 0.059 − 0.0629 − 0.0669 − 0.0708 − 0.0748 − 0.0787 (1.5 − 1.6 − 1.7 − 1.8 − 1.9 − 2) 0.8637 to 0.8645 (21.939 to 21.96) 0.8677 to 0.8685 (22.040 to 22.061) 0.0031 to 0.0048 (0.080 to 0.122)
in. in. in. in.
(mm) (mm) (mm) (mm)
1.7706 to 1.7716 (44.975 to 45) 1.7755 to 1.7785 (45.1 to 45.175) (1) 0.0039 to 0.0078 (0.100 to 0.2) 0.0025 to 0.005 (0.064 to 0.129)
in. (mm)
0.0039 − 0.0059 − 0.0078 − 0.0098 − 0.0118 (0.1 − 0.15 − 0.2 − 0.25 − 0.3)
Epicyclic final drives Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of driven gear shims (9, fig. 5) . . . . . . . . . . . . . . Axle pivot Axle clearance on pivot between body and support . . . . . . Maximum permitted wear clearance . . . . . . . . . . . . . . . . . . . Diameter axle pivot front pin (3, fig. 7) . . . . . . . . . . . . . . . . .
in. (mm)
12 : (12 + 60) = 1 : 6 0.0303 to 0.0326 (0.77 to 0.83)
in. (mm) in. (mm) in. (mm)
0.0118 to 0.0433 (0.3 to 1.1) 0.0787 (2) 2.0729 to 2.0736 (52.652 to 52.671) (continued)
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
3
DATA (cont)
Installed front bush internal diameter (1, fig. 3) . . . . . . . . . . . . . . .
in. (mm)
2.0755 to 2.0783 (52.720 to 52.790) (1)
Clearance between pin (3) and bush (1) . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0019 to 0.0054 (0.049 to 0.138)
Outside diameter of rear bush (6) installed in the bevel pinion support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
3.8984 to 3.8995 (99.020 to 99.050)
Inside diameter of rear bush (5) installed in the axle pivot support
in. (mm)
3.9033 to 3.9063 (99.146 to 99.221) (1)
Assembly clearance between the two bushes . . . . . . . . . . . . . . . .
in. (mm)
0.0037 to 0.0079 (0.096 to 0.201)
Thickness of the front (2) and rear (4) front axle thrust washers .
in. (mm)
0.1948 to 0.1968 (4.95 to 5.00)
(1) Measurement to be obtained without reaming
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Front axle Bevel crown wheel to differential gearbox retaining bolt (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
Safety tab retaining bolt (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
60 to 70
6.1 to 7.1
Bevel pinion shaft locknut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 35 x 1.5
294
30
Differential bevel gear support to axle retaining bolt (C4) . . . . . . .
M 12 x 1.25
Steering knuckle pin retaining bolt (C5) . . . . . . . . . . . . . . . . . . . . . .
M 10 x 1.25
55 to 67
5.6 to 6.8
Wheel hub bearing locknut (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 70 x 2
392
40
Epicyclic final drive housing retaining bolt (C7) . . . . . . . . . . . . . . . .
M 10 x 1.25
55 to 67
5.6 to 6.8
Front axle support to engine retaining bolt (C8) . . . . . . . . . . . . . . .
M 18 x 1.5
310 to 380 31.6 to 38.7
Front axle pivot front and rear supports retaining bolt (C9) . . . . . .
M 18 x 1.5
370 to 410 37.7 to 41.8
Differential housing support cap retaining bolt (C10) . . . . . . . . . . .
M 12 x 1.25
119 to 144 12.1 to 14.7
Ring nut fastening the steering control hydraulic cylinder to the front axle (C11) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
630 to 670 64.2 to 68.3
Bolt retaining steering control linkage ball joint (C12) . . . . . . . . . . .
−
242 to 299 24.6 to 30.5
Rim to disk retaining bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 18 x 1.5
170 to 208 17.3 to 21.2
119 to 144 12.1 to 14.7
119 to 144 12.1 to 14.7
87744428A − 11 − 2007
4
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 TIGHTENING TORQUES
C5 55 ÷ 67Nm
C6 − 392 Nm
26125
C7 55 ÷ 67Nm
1
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
5
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. 380000251
Front axle overhaul stand.
380000227
Front differential unit removal−installation hook.
380000255
Front axle differential casing overhaul support.
X 380000268
Wrench for front bevel drive pinion ring nut.
X 380000248
Bevel pinion bearing adjustment tool (with 50118).
X 380000257 380000249
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).
50169
Pins (M 12 x 1.25) for front axle and cover.
50165
Pins (M 16 x 1.25) for front axle wheels disassembly/assembly.
Front bevel drive pinion lock key. Universal gauge for positioning of front bevel drive pinion.
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). Construct in UNI C40 material.
26135
2
87744428A − 11 − 2007
6
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
27892
3 Tool to be made for front axle wheel disassembly−assembly (Mark tool with No. 50165 − Measurements in mm) Make in UNI C40 material.
27893
4 Tool to be made for front axle gear unit cover disassembly−assembly (Mark tool with No. 50169 − Measurements in mm) Make in UNI C40 material.
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
7
8
7
9
10 26128
X
5 Cross−sectional views of front axle H4 = 3.7401 in. (95 mm). Nominal distance between 9. Epicyclic reduction unit driven gear shims. crown wheel axis and greater diameter of the pinion. 10. Steering knuckle adjustment plates. 1. Thickness of sun pinion thrust washers. 11. Thickness of bevel pinion position adjustment 2. Sun pinions. spacer. 3. Bevel crown wheel. 12. Thickness of bevel pinion bearing adjustment 4. Planet pinions. spacer. 5. Differential casing. 13. Seal. 6. Bevel crown wheel bearing adjustment shims. 14. Cross pin for planet pinions. 7. Axle shaft. 15. Crown wheel bearing adjustment ring nut. 8. Axle shaft bush (7).
Note − On assembly apply a bead of sealing compound to the surfaces X as indicated on page 29.
87744428A − 11 − 2007
8
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
1
2
3
4
5
26062
6 Sections of front axle brake 1. 2. 3.
Brake drive piston. Brake wear disk. Guide pin.
87744428A − 11 − 2007
4. 5.
Brake disk. Seals.
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
9
7 Cross−sectional view of front axis pivot 1. 2. 3. 4.
Axle pivot front bush. Front thrust washer. Axle pivot front pin. Rear thrust washer.
5. 6.
Rear bush installed on axle support. Rear bush installed on bevel drive−differential support.
DESCRIPTION AND OPERATION Tractors T4040 and T4050 are provided with a centrally pivoting front axle with pivot and drive shaft coaxial to the tractor longitudinal axis. The drive shaft is not fitted with universal joints.
The differential has two planet pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which do not require any maintenance.
87744428A − 11 − 2007
10
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
OP. 25 100 30 FRONT AXLE, ASSEMBLY Removal−Installation
DANGER Lift and handle all heavy parts using suitable lifting equipment. Make sure that the load is supported by means of suitable slings and hooks. Check that no one is in the vicinity of the load to be lifted.
Proceed as follows:
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 bolts (1) and remove the front mudguard supports (2).
1
2
25575
8 2. Attach a nylon sling to the front ballast (1), extract the locking pin; lift the ballast and remove to a safe position.
1
25577
9
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 3. Unscrew the bolts (1) and remove the drive shaft guard (2).
1
11
2
25576
10 4. Remove the circlip (2), slide the sleeve (1) towards the rear and free the drive shaft from the front axle.
1
2
25584
11 5. Hook the front of the tractor, with a chain (1), to a hoist.
12 6. Raise the tractor and position a fixed stand under the engine sump.
25581
13
87744428A − 11 − 2007
12
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
7. Unscrew the retaining bolts and remove the front wheels.
25582
14 8. Disconnect the steering cylinder control pipes (1).
15 9. Fasten a chain (1) to the front axle and to the hoist, then make it take up the strain.
16 10. Unscrew the bolts (1) fastening the rear support of the front axle.
17 87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
13
11. Remove the front axle front support retaining bolts (1).
12. To refit the front axle on the tractor, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 18
−
Position the axle, tighten the front and rear supports to the relative support.
−
Reconnect the power steering pipes.
−
Fit the front wheels.
−
Using the hoist, raise the front part of the tractor.
−
Extract the fixed stand.
−
Connect the drive shaft and position the guard.
−
Refit the two front mudguards.
−
Attach a nylon sling to the front ballasting, fit and secure in position with the lock rod.
−
Respect the tightening torque values prescribed on page 3.
87744428A − 11 − 2007
14
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
OP. 25 100 38 FRONT AXLE Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Note − Front axle overhaul operations must be carried out on stand no. 380000251.
25587
19 1. Unscrew the plug (1) and drain the oil from the axle casing.
1 25588
20 2. Unscrew plug (1) on the left−hand epicyclic final drive casing; repeat the same operation on the right−hand casing.
1
25589
21 3. Remove the front axle rear support (1); remove the front support and washer.
1
25590
22 87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 4. Unscrew the left−hand side gear 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).
15
2
1
25594
23 5. Remove the driving gear stop (2) circlip (1).
1
2
25595
24 6. Remove the driving gear stop (2) circlip (1, fig. 24).
1
25596
25 7. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
1
2
25597
26
87744428A − 11 − 2007
16
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
8. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).
1
25598
27 9. Remove the wheel hub (1) together with the epicyclic crown (2). Recover all disassembled parts.
2
1
25599
28 10. Unscrew the three stub axle lower pin retaining bolts (1). Recover the lower pivot pin and the related adjustment shims.
1
25600
29 11. Unscrew the three mudguard support (2) retaining bolts (1).
1
2
25601
30 87744428A − 11 − 2007
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.
17
2 1
25602
31 13. Unscrew the axle shaft (1) retaining bolt (2).
2
1
25603
32 14. Using a crowbar, remove the axle shaft (1, fig. 32). 15. To disassemble the right−hand final drive follow the operations carried out for left−hand final drive disassembly, from operation no. 7 to operation no. 17.
25604
33 16. 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.
1
2
3
25606
34
87744428A − 11 − 2007
18
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
17. Fit tool 380000255 (1) in the vice on a work bench, lock the bevel drive−differential support in the tool and remove the chain.
1
2
18. Unscrew the bolt (2) and recover the ring nut locking plate (3). Remove the differential lock control internal pipe.
3
25607
35 19. Unscrew the bevel drive−differential support cap (1) retaining bolts (2) and remove.
2
1
25612
36 20. Remove the crown wheel−differential unit (2) from the casing (1).
1
2
25613
37 21. Remove the circlip (1) from the splined shaft (2).
1
2
25614
38 87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 22. Straighten the staking on the splined shaft lock nut (1).
19
1
25615
39 23. Unscrew the nut with wrench 380000268 (1) keeping the bevel pinion shaft locked with wrench 380000257.
1
25616
40 24. Remove the splined shaft stop ball (1).
1
25617
41 25. Acting on the rear part, extract the bevel pinion shaft (1) and recover the spacer, adjusting shims and the bearing.
1
25618
42
87744428A − 11 − 2007
20
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
26. Using a screwdriver, detach and remove the dust seal, seal (1) and rear bearing.
1
27. To assemble the front axle, proceed as follows:
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. −
Refer to the illustrations on pages 7 and 8 for the positioning of the various parts.
−
Respect the tightening torques prescribed on page 3.
−
Carry out the adjustments described on pages 22 to 31.
−
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.
−
Reconnect the bevel drive−differential support to the front axle casing.
−
Fit the axle shaft and screw.
−
Fit the stub axle, the adjusting shims, lower and upper pivot pins, mudguard support and screws.
−
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.
87744428A − 11 − 2007
25619
43
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
21
STUB AXLE ADJUSTMENT Proceed as follows.
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
28. Smear AMBRA GR 9 grease on the outer races of the bearings and fit the upper cover, without the plates, but with tool 380000235 (2). Tighten the retaining bolts (C5, page 3) to a torque of 55 to 67 Nm (5.6 to 6.8 kgm).
1
2
24076
44 29. Fit the lower cover without adjustment plates, lubricate the three retaining bolts with engine oil. 30. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow excess grease to escape.
24077
45 31. 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.
1
32. Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts.
24078
46
87744428A − 11 − 2007
22
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
33. Calculate the average of the three values measured. The total thickness of the adjustment plates (10, fig. 9) to be fitted under the lower cover will be given by:
S3 = H
24079
If necessary, round the value down to the next 0.0019 in. (0.05 mm).
34. Partially unscrew the lower cover bolts, insert the plates (10, fig. 9) and tighten the bolts (C5, page 3) to a torque of 55 to 67 Nm (5.6 to 6.8 kgm).
35. Check that the torque necessary to rotate the casing is 2.9 to 7.8 Nm (0.3 to 0.8 kgm), without considering the initial peak torque.
36. If the torque value measured is greater than the prescribed value, increase the thickness of the shims; if the measured value is less than the prescribed value, reduce the thickness of the shims.
37. Assemble the grease fittings in the upper and lower covers and grease the assembly.
87744428A − 11 − 2007
10 47
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
23
BEVEL DRIVE ADJUSTMENTS Adjusting the preloading on the bevel drive shaft bearings (12, fig. 9).
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. 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 − Place the tool 50118 (see fig. 2) between the tool 380000248 (1) and the bearing (2).
24584
48 2. Using the micrometer, measure the distance (H1) between the upper surface and the tip of 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. 48), in the bevel drive−differential housing, using tool 380000255, complete with outer bearing races, held in the vice.
24585
49 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, fig. 9) required is given by: S = H2 − H1 + 0.0019 in. (0.05 mm)
24586
50
87744428A − 11 − 2007
24
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
If necessary, round the adjustment shim (12) value up to the nearest 0.0019 in. (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, fig. 9). 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.
1
3
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 ± C where: H4 = 3.7401 in. (95 mm). Nominal distance between the crown wheel axis and the large diameter base of the pinion (see fig. 9). 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 shim (11, fig. 9) will be given by: S = H3 − H5 where: H3 = micrometer reading; H5 = corrected nominal distance between the crown wheel axis and the large diameter base of the pinion. 87744428A − 11 − 2007
24588
51
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
25
Example −
Distance measured using micrometer H5 = 3.8582 in. (98 mm).
−
Nominal distance between crown wheel axis and large diameter base of H4 = 3.7401 in. (95 mm).
−
Correction value C = + 0.0078 in. (0.2 mm).
−
Corrected nominal distance H5 = 3.7401 + 0.0078 = 3.748 in. (95 + 0.2 = 95.2 mm).
−
Thickness of adjustment shim S = 3.8582 − 3.748 = 0.1102 in. (98 − 95.2 = 2.8 mm).
−
Correction value C = − 0.0078 in. (0.2 mm).
−
Corrected nominal distance H5 = 3.7401 − 0.0078 = 3.7322 in. (95 − 0.2 = 94.8 mm).
−
Thickness of adjustment shim S = 3.8582 − 3.7322 = 0.1259 in. (98 − 94.8 = 3.2 mm).
−
Correction value C = 0 mm.
−
Corrected nominal distance H5 = H4 = 3.7401 in. (95 mm).
−
Thickness of adjustment shim S = 3.8582 − 3.7401 = 0.1181 in. (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, spacers and pre−determined adjustment shims (11 and 12). 14. Fit the O−ring (1) on the bevel pinion shaft.
1 15. Insert the spacer on the pinion and, after having carefully greased the outer surface, fit the anti− rotation ball.
24589
52
87744428A − 11 − 2007
26
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 294 Nm (30 kgm), while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.
2
24590
53
19. With torque wrench 380001633 (1) fitted on pinion retaining wrench 380000257 (2), check that the pinion rolling torque, without oil seal (13, fig. 9) and relative dust seal, is 0.5 to 1 Nm (0.050 to 0.100 kgm). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (12, fig. 9), if the torque is greater than the prescribed value, fit a thicker adjustment shim.
20. Unscrew the ring nut and fit the seal (13, fig. 9) and the relative dust seal ring. Tighten the nut to a torque value of 294 Nm (30 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 the oil seal and relative dust seal, is ≤ 0.50 Nm (0.050 kgm). Finally, secure the ring nut and fit the circlip on the bevel pinion shaft.
24587
54
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
27
Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth. Proceed as follows. 24112
22. Install the differential assembly complete with crown wheel and inner bearing rings on the differential bevel drive support.
24112
55 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, fig. 9), that was previously removed during the axle overhaul operation, and the relative circlip.
24591
56 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 to 59 Nm (4 to 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. 58).
1
24592
57 27. Repeat the measurement in a further two positions 120° and compare the average of the three values (Gm) with the prescribed normal backlash: 0.0070 to 0.0090 in. (0.18 to 0.23 mm) average 0.0078 in. (0.20 mm). If the measured backlash exceeds the prescribed value, fit a thinner adjustment shim (4, fig. 9).
1
24593
58
87744428A − 11 − 2007
28
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, fig. 9) to fit on the bevel drive− differential support will be given by: S = Sp − {(Gm − 0.20) 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, fig. 9), the value being given by: S = Sp + {(0.20 − 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, fig. 9) 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 0.007 to 0.009 in. (0.18 to 0.23 mm). 29. Using wrench 380000252 (1) turn the adjustment ring nut and:
1 24592
59 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 to 1.5 Nm (0.10 to 0.15 kgm) where: A2 = pinion−crown wheel rolling resistance torque; A1 = rolling resistance torque of pinion only as previously measured;
1
24594
60
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
29
1 to 1.5 Nm (0.10 to 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 of 119 to 144 Nm (12.1 to 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. 0.0787 in. (2 mm)) along the marked line shown in the drawing below.
24591
61
Mastic application diagram for assembly of bevel drive unit and epicyclic final drive unit. The types of mastic to use are listed on page 1, Section 00.
24595
62
87744428A − 11 − 2007
30
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
OP. 25 102 24 FRONT AXLE DIFFERENTIAL Overhaul In case of differential assembly overhaul it is necessary to adjust the backlash between the teeth of the sun and planet pinions.
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. 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.
24597
63
6. Repeat the above operations to measure the endfloat on the right hand side gear (Gd). The side gear endfloat will be 0.0098 in. (0.25 mm). Therefore the shims to be inserted in the differential housing are given by: Ss = Gs − 0.0098 in. (0.25 mm) for the left−hand sun gear; Sd = Gd − 0.0098 in. (0.25 mm) for the right− hand sun 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 0.0098 in. (0.25 mm).
87744428A − 11 − 2007
24598
64
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
31
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE WITH BRAKE Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
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
65
1. Remove the plug (1) and drain the oil from the epicyclic final drive.
1
25559
66 2. Unscrew the left−hand side final drive casing bolts. Screw in the two pins 50169 and, using an extractor (1), fitted on the oil drainage plug, detach the epicyclic final drive casing (2) and remove.
1
2
25561
67
87744428A − 11 − 2007
32
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
3. Remove the circlip (1) and extract the outer brake disk (2).
68 4. Recover the hub (1) on the brake disk.
1
25563
69 5. Unscrew the retaining bolts and remove the drive fixed gear (1) using two bolts as extractors. 6. To refit the front epicyclic final drive, proceed as follows.
1
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. − − − − − −
− −
Refer to the illustrations on pages 7, 8 and 9 for the positioning of the various components. Respect the tightening torque values prescribed on page 3. Refit the drive fixed gear. Refit the brake disk hub. Fit the outer brake disk and secure in position. Before reassembling the epicyclic final drive casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 0.0787 in. (2 mm)) along the marked line shown on page 30. 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).
87744428A − 11 − 2007
25562
70
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
33
WHEEL HUB SEAL Replacement
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows 1. Carry out operation 25 108 30 Front epicyclic final drive with brake, only removal (see page 32). 2. Remove the hub casing (1). 71 3. Remove the seal and fit the pins (1) of tool 380000286.
72 4. Carefully clean the seat and position the seal (1), ready for fitting.
NOTE: The external surface on the seal (1), indicated by the arrow, does not require lubrication.
73 5. Fit the seal (2) fully tightening the screws on tool 380000286 (1). 6. To refit the wheel hub parts, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. − −
Remove tool 380000286 from the hub. Carry out operation 25 108 30 Front epicyclic final drive with brake, only installation (see page 33). 74
87744428A − 11 − 2007
34
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
Op. 25 108 30 FRONT EPICYCLIC FINAL DRIVE Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
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. Remove the plug (1) and drain the oil from the epicyclic final drive.
75
1
25589
76 2. Unscrew the left−hand side gear 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).
1
2
25594
77
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 3. Remove the securing ring (1) on the wheel hub bearing lock ring (2).
1
35
2
25597
78 4. Remove the lock nut on the wheel hub bearings using wrench 380000295 (1).
1
25598
79 5. Remove the wheel hub (1) together with the final drive fixed gear (2). Recover all disassembled parts.
1
2
6. To refit the front epicyclic final drive, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Refer to the illustrations on pages 7, 8 and 9 for the positioning of the various components.
−
Respect the tightening torque values prescribed on page 3.
−
Assemble the wheel hub and the epicyclic final drive fixed gear.
25599
80
87744428A − 11 − 2007
36 −
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1 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. Measure the rolling resistance (Rt) of the wheel hub using the relative torque wrench, or a torque meter and cord positioned on the base of the wheel disk flange. Loosen the ring nut by half a turn and measure the rolling resistance (R) as described previously. The difference between the two measurements is the rolling torque value of the wheel hub bearings (Rc): Rc = Rt − R = 5.9 ÷ 14.7 Nm (0.6 ÷ 1.5 kgm) or if measured with a torque meter. Rc = Rt − R = 4.8 ÷ 12 kg. If the measurement is less than 5.9 Nm (0.6 kgm) or with the torque meter on 4.8 kg it is necessary to replace the affected parts and repeat the check.
−
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. 0.0787 in. (2 mm)) along the marked line shown on page 30.
−
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).
−
Fit the track rods.
87744428A − 11 − 2007
81
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
37
WHEEL HUB SEAL Replacement
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows 1. Carry out operation 25 108 30 Front epicyclic final drive with brake, only removal (see page 35). 2. Remove the hub casing (1) and the spacer. 82 3. Remove the worn seal, carefully clean the seat and position the new seal (1) on the seat fitting.
NOTE: The external surface on the seal (1), indicated by the arrow, does not require lubrication.
83 4. Fit tool 380000287 (2) on the hub and fit, by a few mm, the seal (3) using a drift (1).
84 5. Fully fit the seal in position using the ring nut and wrench 380000295 (1). 6. To refit the wheel hub parts, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. − −
Remove tool 380000287 from the hub. Carry out operation 25 108 30 Front epicyclic final drive with brake, only installation (see page 36). 85
87744428A − 11 − 2007
38
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
OP. 25 108 46 or 25 108 47 STEERING KNUCKLE PINS AND BEARINGS Replacement
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. 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). 5. Screw in the nut (3) to drive the pin out of its bore.
24596
86 6. Using extractor tool 380000234 (1) remove the steering knuckle bearings.
1
7. Re−install the steering knuckle bearings using a suitable drift.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Carry out the following adjustments.
24599
87
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
39
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. It does not require any type of manual operation and significantly reduces (but does not completely eliminate) wheel slipping. The difference in revolutions, between the side gears and the differential casing when a wheel begins to slip as a result of grip loss, is impeded by clutch assemblies that are compressed by axial thrusts 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
88 LIM−SLIP self−locking differential
OP. 25 102 27 FRONT AXLE DIFFERENTIAL WITH LIM− SLIP UNIT Overhaul
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
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 clearly marked, so as not to interchange the parts during assembly operations. 4. Remove the right and left−hand bearing adjustment ring nuts (Gd) from the bevel crown wheel. 5. Remove the bolts (C9), 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. 89
87744428A − 11 − 2007
40
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
Disassemble the LIM−SLIP self−locking differential lock as follows. 7. Remove the retaining bolts (1) from the differential half−casing. 8. Open the differential casing (6). 9. Remove the half−casing (7) the differential pin (4), complete with the planet gears (3), the thrust washers (2) and the pins (9). 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), the friction disk (11), the 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 show signs of wear. 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
90 LIM−SLIP self−locking differential
14. Refit the 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 27. 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 29.
z 27967
91 Friction parts detail
LIM−SLIP self−locking differential friction disks Item no.
Description
Amount
Thickness in. (mm)
Maximum wear per disk in. (mm)
10
Metal disk
10
0.0590 (1.5)
−
11
Friction disk
2
0.1102 (2.8)
0.0039 (0.10)
12
Friction disk
8
0.0629 (1.6)
0.0059 (0.15)
87744428A − 11 − 2007
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
41
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 0.2362 in. (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 prescribed pressure. 2. Position the steering wheel at the middle of its travel, with one spoke 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).
92
5. Measure the distance (1) between the front inside edges of the rims. 6. Turn both front wheels through 180° 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 0.2362 in. (6 mm). The rotation of the wheels through 180° is required in order to eliminate the effect on the measurement of any eventual wear on the rims.
1
2
24666
93 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. 92) stays the same on both sides of the steering control cylinder (2, fig. 92). After having adjusted the toe−in to within the prescribed limits, tighten lock nut (1).
94
87744428A − 11 − 2007
42
SECTION 25 − FRONT AXLE MECHANICAL TRANSMISSION − CHAPTER 1
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
1
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION Chapter 1 − Rear axle mechanical transmission
CONTENTS Section
Description
Page
27 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
27 100
Removal−Installation−Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
BEVEL DRIVE AND DIFFERENTIAL DATA 9/40 = 1:4.4(1)
Bevel drive gear ratio Clearance between sides of bevel gear pair teeth . . . . . . .
in. (mm)
11/39 = 1:3.54(2)
0.0070 to 0.0090 (0.18 to 0.23)
Type of differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with two planet gears
Mechanically controlled differential lock . . . . . . . . . . . . . . . .
by means of pedal
Side pinion internal seat diameter (5, fig. 8) . . . . . . . . . . . .
in. (mm)
0.9464 to 0.9472 (24.040 to 24.061)
Side pinion pin diameter (19, fig. 8) . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.9424 to 0.9433 (23.939 to 23.960)
Clearance between side pinions and pins . . . . . . . . . . . . . .
in. (mm)
0.0031 to 0.0048 (0.080 to 0.122)
Diameter of crown wheel pinion hub seats on differential housing (3, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.7354 to 1.7369 (44.080 to 44.119)
Diameter of crown wheel pinion hubs (17, fig. 8) . . . . . . . .
in. (mm)
1.7307 to 1.7322 (43.961 to 44.000)
Clearance between crown wheel pinion hubs and seats . .
in. (mm)
0.0031 to 0.0062 (0.080 to 0.158)
Bevel gear bearing adjustment and bevel pinion clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Thickness of bevel gear bearing adjuster rings and bevel gear coupling clearance (21, fig. 8) . . . . . . . . . . . . . . . . . . . (1)
18.64 mph (30 km/h) model − (2) 24.85 mph (40 km/h) model.
see pages 21 to 24 in. (mm)
0.0059 − 0.0078 − 0.0196 (0.15 − 0.20 − 0.50) (continued)
87744428A − 11 − 2007
2
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 BEVEL DRIVE AND DIFFERENTIAL DATA (cont)
Clearance between sides of sun and planet pinion teeth Thickness of differential crown wheel shim adjustment rings (16, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thickness of differential side pinion shim adjustment rings (4, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0059 (0.15)
in. (mm)
0.0551 − 0.0590 − 0.0629 − 0.0669 − 0.0708 − 0.0748 − 0.0787 (1.4 − 1.5 − 1.6 − 1.7 − 1.8 − 1.9 − 2.0)
in. (mm)
0.0578 to 0.0602 (1.470 to 1.530)
Adjustment of clearance between the sun and planet pinion teeth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see pages 24 and 25
Adjustment of differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 20
Thickness of differential lock control fork adjuster . . . . . . . . . .
in. (mm)
0.0196 (0.5)
in. (mm)
8.6614 (220)
in. (mm)
6.2007 (157.5)
Differential lock control fork spring (Mechanical control): −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
length of springs under load 177 to 195 N (18.1 to 19.9 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FINAL DRIVE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
epicyclic with three planet gears with straight toothing
Gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13:(13+65)= 1:6
Thickness of side pinion shim rings (8, fig. 8) . . . . . . . . . . . . . .
in. (mm)
Adjusting end float of planet gear casing . . . . . . . . . . . . . . . . . . Thickness of axial clearance adjuster rings for side pinion casing (10, fig. 8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87744428A − 11 − 2007
0.0393 (1) see page 31
in. (mm)
0.1771 − 0.1811 − 0.1850 − 0.1889 − 0.1929 − 0.1968 − 0.2007 − 0.2047 − 0.2086 − 0.2125 − 0.2165 − 0.2204 − 0.2244 − 0.2283 (4.5 − 4.6 − 4.7 − 4.8 − 4.9 − 5.0 − 5.1 − 5.2 − 5.3 − 5.4 − 5.5 − 5.6 − 5.7 − 5.8)
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
3
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Transmission gearbox − clutch retaining bolts (C1, fig. 1) . . . . . . .
−
117 to 129
11.9 to 13
Transmission gearbox cover − PTO retaining bolts (C2) . . . . . . . .
−
20 to 25
2 to 2.5
PTO driven shaft ring nut (C3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
256 to 309
26 to 31.5
Transmission gearbox lower cover retaining bolts (C4) . . . . . . . . .
−
43 to 51
4.4 to 5.2
Bevel pinion shaft ring nut (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
280 to 309
28.5 to 31.5
Gear driven shaft bearings retaining bolts (C6) . . . . . . . . . . . . . . .
−
84 to 93
8.6 to 9.5
Bevel crown wheel retaining bolt (C7) . . . . . . . . . . . . . . . . . . . . . . .
−
131 to 144
13.3 to 14.7
Reduction shaft bearings support retaining bolts (C8) . . . . . . . . . .
−
47 to 51
4.8 to 5.2
Reduction gearbox − transmission gearbox retaining bolts (C9) .
−
135 to 149
13.8 to 15.2
Drive wheel axle retaining bolts (C10) . . . . . . . . . . . . . . . . . . . . . . . .
−
285 to 345
29 to 35.2
Plate disk − drive wheel hub retaining bolts (C11) . . . . . . . . . . . . .
−
264 to 319
264 to 32.5
Plate disk − drive wheel rim ring nut (C12) . . . . . . . . . . . . . . . . . . . .
−
217 to 262
22 to 26.7
87744428A − 11 − 2007
4
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 TIGHTENING TORQUES C2 − 20 to 25 Nm
C1 − 117 to 129 Nm
Z=43
C6 − 84 to 93 Nm
C5 − 280 to 309 Nm
C4 − 43 to 51 Nm
C3 − 256 to 309 Nm C9 − 135 to 149 Nm
C7 − 131 to 144 Nm
C8 − 47 to 51 Nm
C10 − 285 to 345 Nm
C11 − 264 to 319 Nm
C12 − 217 to 62 Nm
25999
1
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
5
List of specific tools required for the various operations described in this Section.
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.
380000227
Clutch casing lift hook.
380000301
Rotating stand for overhaul operations.
380001626
Grooved wrench for bevel gear.
24663
2 Tool to be made for disassembly−assembly of the final drives, to be used with 50114. (Mark part with No. 50091 − Measurements in mm) Make in Aq 42 D material. 1. Make 2 tie−rods in C 40 bon material.
87744428A − 11 − 2007
6
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
26258
1 3 Tool to be made for lateral gear removal−installation, use with a part of 50091. (Mark part with No. 50114 − Measurements in mm) Make in Fe 42 C material − (*) Measurement according to hoist seat.
26260
4 Tool to be constructed for adjusting differential lock sleeve travel. (Mark the tool with no. 50041 − Measurements in mm) Make using C40 material.
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
7
26000
5 Tool to be constructed for securing the transmission gearbox to the rotating stand. (Mark part with No. 50156 − Measurements in mm) Construct in Aq 42 material − (1) Rotating stand axle
87744428A − 11 − 2007
8
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
6 Series of guide pins (no. 2) to be constructed for differential support removing−refitting. (Mark the pins with no. 50164 − Measurements in mm) Make using C40 material
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
1
2
3
11
10
9
4
9
8
7
6
5
26001
7 Longitudinal section of gearbox−transmission 1. 2. 3. 4. 5. 6.
Gearbox driving shaft. PTO control shaft. Gearbox driving gear. Bevel crown wheel. Bevel pinion shaft. Gearbox low − mid − upper range gear engagement sleeve.
7. 8. 9. 10. 11.
Low − mid driven gear shaft. Low − mid − upper range gear engagement. Gearbox driven shaft. 1st and 2nd gear engagement synchroniser. 3rd and 4th gear engagement synchroniser.
87744428A − 11 − 2007
10
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
1
2
3
4
5
6
7
8
9
10
11
12
A B
16 21
20
19
18
15
14
13
17
26002
8 Sectional view of transmission A. 0.3188 to 0.3228 in. (8.1 to 8.2 mm). Differential lock engage sleeve travel. B. 0.0078 to 0.0157 in. (0.2 to 0.4 mm). Final drive planet pinion support end float. 1. Bevel crown wheel bearing support. 2. Differential lock control fork. 3. Differential casing. 4. Shim ring. 5. Planet gear. 6. Differential lock spring. 7. Bevel crown wheel bearing support. 8. Shim rings. 9. Differential output half−shaft. 10. Side pinion casing support (13) axial clearance adjuster shim.
87744428A − 11 − 2007
11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21.
Wheel axle shaft. Seal. Final drive planet gear support. Final drive planet gear. Bearing. Sun gear clearance adjuster ring. Sun gear. Bevel crown wheel. Side pinion pin (5). Differential lock engagement sleeve. Adjuster rings for bearings and coupling clearance between ring bevel gear and pinion.
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
11
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 side pinions and is fitted with a mechanically or hydraulically operated differential lock.
Final drives are of the pinion type and are controlled by the bevel gear pair output half−shafts, the same shafts that control the footbrakes.
BEVEL DRIVE AND DIFFERENTIAL TROUBLESHOOTING Problems
Possible Causes
Transmission is noisy while the 1. Incorrect adjustment or wear tractor is moving, even when the of sun and planet gears. gears are in neutral (not due to Final drives).
Solutions Remove the rear transmission gearbox and replace the worn parts, then correctly adjust the differential gears (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 trac- 1. Internal part faulty. tor 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 is noisy and assem- 1. Insufficient coupling clearan- Remove the rear transmission gearbly overheats. ce between the teeth of the pi- box and correctly adjust the ring bevel nion and of the bevel crown gear bearings (page 21). wheel.
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. 2. Excessive clearance between wheel axle shaft spline and epicyclic final drives.
Solutions Remove the final drive housing and replace the damaged parts. Remove the final drive housing and replace the damaged parts.
87744428A − 11 − 2007
12
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
Op. 27 106 16 REAR TRANSMISSION GEARBOX Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. To remove the gearbox, proceed as follows. 1. Carry out operation 21 118 10 or 21 118 12 Rear transmission housing−gearbox, only removal (see Section 21, Chapter 1). 2. Carry out operation 21 118 85 Gearbox transmission casing, only removal of gearbox from casing (see Section 21, Chapter 1). 3. Carry out operation 31 112 20 Mechanically engaged PTO, only removal (see Section 31, Chapter 1). 4. Remove the pin (1) from the differential lock fork (2).
26003
9 5. Unscrew the retaining bolts (1) differential lock rod (2) stop plate.
26004
10 6. Extract the differential lock rod (1) removing the fork (2) and the return spring (3) from inside the transmission gearbox.
26005
11
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
13
7. Unscrew the retaining bolts (1) that support the ring bevel gear (2), removing the supports and adjuster shims.
26007
12 8. Remove the ring bevel gear (1) from inside the transmission gearbox.
26008
13 9. Extract the two stop pins (1) of the final drive control.
26009
14 10. Unscrew the rod support retaining bolts (1).
26010
15
87744428A − 11 − 2007
14
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
11. Extract the retaining pins (1) of the fork and final drive control nib.
26011
16 12. Remove the two rods (1), the forks and the final drive control nib (2) with the relative poppet balls and return spring from the front section of the transmission gearbox.
26012
17 13. Remove the retaining circlip (1) from the pinion shaft rear gear (2).
26013
18 14. Remove the pinion shaft rear gear (1).
26014
19 87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
15
15. Remove the pinion ring nut safety tab pressure washer (1).
26015
20 16. Rotate the transmission gearbox (3) through 180°. Fit tool 380001626 (1) on the rear of the pinion shaft, position the 2.1653 in. (55 mm) wrench (2) on the internal ring nut; using tool 380001626 unscrew the ring nut and take out the pinion shaft from the rear of the transmission gearbox.
26016
21 17. Remove the gears (1) from inside the transmission gearbox. 18. To refit the various parts in the rear transmission gearbox, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
With the transmission gearbox facing upwards, place the gears and the pinion shaft in the housing, via the opening on the PTO housing.
−
Insert the 2.1653 in. (55 mm) wrench on the internal ring nut; using a torque wrench and tool 380001626, move the end of the pinion so as to tighten the ring nut to a torque of 280 to 309 Nm (28.5 to 31.5 kgm) and squeeze the safety washer.
−
Insert the remaining gears on the pinion shaft.
−
Fit the two rods, forks and final drive nib.
26017
22
87744428A − 11 − 2007
16
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
−
Check the rolling torque of the pinion, as described on page 21.
−
Fit the differential lock rod with the fork control piston and return spring.
−
Fit the rods, the pinion shaft sleeve forks and the drive shaft sleeve with relative poppet balls and return spring and the rod limit switch pins.
−
Adjust the position of the differential lock engagement sleeve as described on page 20.
−
Before fitting the ring bevel gear, check and (if necessary) adjust the clearance between the side pinion teeth and the crown wheels, as described on page 24.
−
Carry out operation 31 112 20 Mechanically engaged PTO, only installation (see Section 31, Chapter 1).
−
Carry out operation 21 118 85 Gearbox transmission casing, only assembly of gearbox in the casing (see Section 21, Chapter 1).
−
Carry out operation 21 118 10 or 21 118 12 Rear transmission housing−gearbox, only installation (see Section 21, Chapter 1).
−
−
Position the ring bevel gear inside the transmission gearbox, fit the LH ring bevel gear support with the 0.0196 in. (0.5 mm) test shim. Adjust the ring bevel gear bearings and the clearance between the sides of the ring bevel gear teeth, as described on pages 21 to 24.
87744428A − 11 − 2007
Sealing compound application diagram for transmission−gear box casing The types of sealing compound are indicated on page 1, Section 00
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 17
27153
27153
87744428A − 11 − 2007
18
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
Op. 27 110 10 Adjusting the position of differential lock engagement sleeve
CAUTION Always use appropriate tools to align fixing 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 gauge 50041 (2, fig. 4) with the 0.3188 to 0.3228 in. (8.1 to 8.2 mm), shim between the sleeve and the differential casing, so that it makes contact with the sliding surfaces of the sleeve on the casing. 3. Using a crowbar, bring the sleeve into contact with the gauge 50041 and the differential housing, adjusting the fork (1) to the position of the gauge. 26018
23 4. Using a feeler gauge (1), measure the clearance between the control pin (2) and the seat on the rod (3).
26019
24 5. Position the required shim under the differential lock control device and secure in position using the bolts.
26020
25
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
19
ADJUSTING THE BEVEL DRIVE Adjusting the bevel crown wheel bearings and checking the clearance between the sides of the bevel drive teeth
CAUTION Always use appropriate tools to align fixing 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 62.9465 to 69.4660 lbf (280 to 309 Nm). 2. Check that the pinion rolling drag torque is 0.040 to 0.450 kgm, corresponding to a dynamometric force on the mid−upper driven gear range of 5.9 to 62.8 N (0.6 to 6.4 kg). 3. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Fit the LH support (1) on the transmission−gearbox, with a test shim of 0.0196 in. (0.5 mm), tightening the three bolts at 120°, to a torque value of 13.2637 lbf (59 Nm).
26021
26
4. Using a micrometer gauge (1), measure the thickness of the RH support (D1). Fit the support (2), without adjuster rings, on the transmission− gearbox, using the three lubricated bolts set at 120°. 5. Tighten the bolts gradually and alternately and, at the same time, turn the crown wheel to allow the bearings to settle, until the pinion crown reaches a rolling torque which is the same as that measured for the single pinion plus the values shown in the table: 26022
27
ROLLING CROWN 9/40
9/38
1.3 to 2.0 kg 12.7 to 19.6 N
11/39
11/36
1.6 to 2.5 kg 15.7 to 24.5 N
11/32 1.9 to 3.0 kg 18.6 to 29.4 N
87744428A − 11 − 2007
20
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 This torque can be measured with a dynamometer (1) and cord wrapped around the mid−upper gear drive and corresponds to a force on the dynamometer for the single pinion, added to the values shown on the table.
26023
28 6. Use a depth gauge to measure the distance (D2) between the transmission−gearbox and the outer face of the RH support, near the two notches, and calculate the arithmetic mean of the two measured values.
26024
29 7. Use a depth gauge to measure the distance (D3) between the transmission−gearbox and the RH support seat, near the two notches, and calculate the arithmetic mean of the two measured values. 8. The total thickness of the shims to be inserted under the RH and LH supports is given by: S = D3 − D1 − D2 + 0.05 where: 26025
S = total thickness to be inserted (excluding the test shim). D3, D2 and D1 = distances measured. 0.0019 in. (0.05 mm) = oversizing required to reduce the preloading on the bearings generated by the support retaining bolts. If necessary, round off (S) to the nearest 0.0019 in. (0.05 mm).
87744428A − 11 − 2007
30
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 9. Using a dial gauge (1), check the clearance (G) between the sides of the teeth of the bevel gear pair (three measurements at 120° and the arithmetic mean of the three readings) and compare the mean of the three values with the normal prescribed clearance: 0.0070 to 0.0090 in. (0.18 to 0.23 mm), average 0.0082 in (0.21 mm). To compensate for greater measured clearance, consider that the ratio between the normal clearance of the teeth and the equivalent axial movement of the crown wheel has an average value of 1 : 1.4. The axial movement of the crown (Z) will therefore be:
21
1
26026
31
Z = (G − 0.21) x 1.4 where: G = previously measured clearance between the sides of the teeth of the bevel gear pair. 10. The sets of adjuster rings (Sd and Ss) to be inserted on the RH (2) and LH (1) supports are given by:
L−ht
R−ht
Sd = S − Z Ss = Z + 0.5
1
2
where: S = Overall value of adjuster rings (excluding the test shim). Z = Axial movement of the crown wheel previously calculated.
25930
0.5 = Test shim.
32
11. Fit the calculated shims on the supports and check the rolling torque of the pinion−crown wheel assembly and the clearance between the sides of the teeth of the bevel gear pair as described above. Example − Measurement of rolling torque of the bevel pinion shaft = 0.0877 to 0.9891 lbf (0.39 to 4.4 Nm) (on the dynamometer 1.3264 to 14.1180 lbf − 5.9 to 62.8 Nm). − Measurement of thickness (D1) of the RH support = 0.4921 in. (12.05 mm). − Measurement of rolling torque of the pinion− crown wheel assembly = 3.14 Nm (0.320 kgm), corresponding to the force on the dynamometer with a cord wrapped around the mid−upper range gears of 10.1389 lbf (45.1 N). − Measurement of distance (D2) between the transmission−gearbox and the RH support: 1.1830 in. (30.05 mm); 1.1870 in. (30.15 mm).
26027
33
87744428A − 11 − 2007
22
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 D2 = mean = (1.1830 + 1.1870) : 2 = 1.1850 in. [(30.05 + 30.15) : 2 = 30.10 mm].
−
Measurement of distance (D3) between the transmission−gearbox and the RH support seat: 1.6850 in. (42.80 mm); 1.6929 in. (43.00 mm). D3 = mean = (1.6850 + 1.6929) : 2 = 1.6889 in. [(42.80 + 43.00) : 2 = 42.90 mm].
−
Total thickness of the adjustment rings: S = 1.6889 − 0.4744 − 1.1850 + 0.0019 = 0.0314 in. [42.90 − 12.05 − 30.10 + 0.05 = 0.80 mm].
−
Clearance measured between sides: 0.0169 in. (0.43 mm); 0.0177 in. (0.45 mm); 0.0161 in. (0.41 mm). G = mean = (0.0169 + 0.0177 + 0.0161) : 3 = 0.0169 in. [(0.43 + 0.45 + 0.41) : 3 = 0.43 mm].
−
Axial movement (Z), corresponding to the set of shims to be inserted on the LH support: Z = (0.0169 − 0.0082) x 1.4 ≅ 0.0118 in. [(0.43 − 0.21) x 1.4 ≅ 0.30 mm].
−
Thickness of adjuster rings to be inserted on the RH support Sd = 0.0314 − 0.0118 = 0.0196 in. (0.80 − 0.30 = 0.50 mm). Thickness of adjuster rings to be inserted on the LH support Ss = 0.0118 + 0.0196 = 0.0314 in. (0.30 + 0.50 = 0.80 mm).
1
where:
2
3
4
5
0.50 = test shim.
6 Adjustment of the clearance between the sun and planet pinion teeth
7
With the differential disassembled on the bench, proceed as follows. 12. 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. 13. 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.
8 25920
34
H1 25921
35 87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
23
14. Push the crown wheel so that it touches the differential and measure the distance (H2). 15. Repeat the same operations for the RH sun gear.
H2
25922
36 16. The axial movement of the crown wheels (2 and 5) without adjustment rings is given by:
1
Gs or Gd = H1 − H2
2
3
4
5 6
where: Gs = axial movement of LH crown wheel; Gd = axial movement of RH crown wheel;
7
H1 and H2 = are the LH or RH crown wheel measurements.
8
The normal clearance envisaged between the sides of the side pinion teeth is 0.0059 in. (0.15 mm).
25920
37
Therefore, the normal clearance and the equivalent axial movement of the crown wheels has an average ratio of 1:1.7. The axial movement of the sun gears corresponding to the normal clearance is: 0.15 x 1.7 = 0.0098 in. (0.25 mm). Therefore the adjustment rings (1 and 6) to insert on the differential housing will be given by: Ss = Gs − 0.0098 in. (0.25 mm) (for LH crown wheel). Sd = Gd − 0.0098 in. (0.25 mm) (for RH crown wheel). Insert the adjustment rings obtaining a distance which is as close as the value thus obtained (the available values are listed on page 2).
87744428A − 11 − 2007
24
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
Adjustment of the differential lock control pedal stroke The distance (H) between the pedal base and the end of the lining should be 2.2834 to 2.4409 in. (58 to 62 mm).
38 If not, proceed as follows. 1. Loosen the locknut (1), unhook and extract the stop spring (2). 2. Screw or unscrew the fork (3) until the required height for the differential lock pedal from the base is obtained. 3. Insert and hook−up the stop spring and tighten the locknut.
39
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
25
Op. 27 120 10 − 27 120 20 RH OR LH FINAL DRIVE CASING 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. Check that no one is in the vicinity of the load to be lifted.
Proceed as follows. 1. Lock the front wheels using chocks. 2. Carry out operation 90 114 26: Rear roll bar, only removal (see Section 90, Chapter 1). 3. To remove the LH final drive housing, carry out operation 10 216 10: Fuel tank, only removal (see Section 10, Chapter 1). 4. Unscrew the retaining bolts holding the lateral stabiliser strut.
40 5. Fit tool 50091 (1) and adapter 50114 (2) to the final drive housing (3), then position a hydraulic jack (4) under the tool.
41 6. Unscrew the retaining bolts and, using the hydraulic jack, remove the final drive housing (1) and the axle shafts. 7. To refit the final drive casing, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
42 87744428A − 11 − 2007
26 −
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1 Before refitting the casings, supports and covers clean and de−grease the mating surfaces and apply sealing compound (approx. 0.0787 in. (2 mm) in diameter) as shown in figure 43.
−
Insert the axle−shaft in the brake disk and differential.
−
Using tools 50091, 50114 and a hydraulic jack, refit the lateral final drive unit to the rear transmission gearbox.
−
Fit the lateral stabiliser strut bracket.
−
If the LH final drive is removed, carry out operation 10 216 10: Fuel tank, only installation (see Section 10, Chapter 1).
−
Carry out operation 90 114 26: Rear roll bar, only installation (see Section 90, Chapter 1).
27154
43 Diagram of seal compound application for brake assembly and final drives on the transmission casing. The types of sealing compound are listed on page 1, Section 00.
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
27
Op. 27 120 34 DRIVE WHEEL SHAFT Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
With the final drive casing removed from the rear transmission, proceed as follows. 1. Remove the drive wheel shaft lock bolt safety plate (1). 26030
44 2. Unscrew the bolts securing the driven gear support (1) on the drive wheel shaft and remove the safety plate.
26031
45 3. Extract the support (1) from the driven gears and remove the axial clearance adjuster shim from the support.
26032
46
87744428A − 11 − 2007
28
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
4. Connect the lateral final drive (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
47 5. Remove the seal (1). 6. To refit the final drive casing, proceed as follows.
CAUTION 1
Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
For the positioning of the various parts refer to figures 7 and 8.
−
Respect the tightening torques 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.
−
Insert the safety plate and tighten the bolt to the prescribed torque.
−
Adjust the end float of the gear support as follows.
24614
48
7. Using a dial gauge (1), check that the axial clearance of the support (2) is 0.0078 to 0.0157 in. (0.2 to 0.4 mm); if not, adjust the shim (10, fig. 8).
NOTE: The adjustment shims are listed on page 2.
26034
49
87744428A − 11 − 2007
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
29
Op. 27 120 32 EPICYCLIC FINAL DRIVE Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
With the assembly detached from the housing, proceed as follows. 1. Remove retaining ring (1). 2. Extract the pins and remove the gears, complete with the roller bearings. 3. Fit all the parts of the epicyclic final drive, reversing operations 1 and 2.
24620
50
87744428A − 11 − 2007
30
SECTION 27 − REAR AXLE MECHANICAL TRANSMISSION − CHAPTER 1
87744428A − 11 − 2007
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
1
SECTION 31 − MECHANICAL POWER TAKE−OFF Chapter 1 − Mechanical power take−off CONTENTS Section
Description
Page
31 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross−sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
31 112 20
Mechanical power take−off. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
DATA 540 rpm power take−off Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) independent with respect to tractor speed or: 2) synchronised to gearbox
Coupler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located under the steering wheel (RH side) (see page 9 and 10)
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rev/min
2196
PTO revolution speed with engine at max. power of 2300 rpm: − for 540 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rev/min
565
rev/ wheel rev
15.66
rev/ wheel rev
12.50
540 rpm, gearbox synchronized, PTO revolution speed (18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . . . . . . . . . 540 rpm, gearbox synchronized, PTO revolution speed (4WD 24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . . . . Diameter of driven shaft at grooved terminal . . . . . . . . . . . .
13/8” (6 grooves) (continued)
87744428A − 11 − 2007
2
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
DATA (cont)
Power take−off − 540/540E rpm Type (two functions) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1) independent with respect to tractor speed or: 2) synchronised to gearbox
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of hand lever located under the steering wheel, on RH and LH side of driver’s position (see page 9 and 10)
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear RH side of the driver’s seat
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .
clockwise
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rev/min
2196
Engine speed with PTO at 540E rpm (750 rpm) . . . . . . . . . .
rev/min
1535 (2132)
rev/min rev/min
565 809
rev/ wheel rev
15.66
rev/ wheel rev
12.50
rev/ wheel rev
22.41
rev/ wheel rev
17.88
in. (mm)
1.9660 to 0.1968 (49.938 to 50.000)
PTO revolution speed with engine at max. power of 2300 rpm: − for 540 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − PTO 540E rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 540 rpm, gearbox synchronized, PTO revolution speed (18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . . . . . . . . .
540 rpm, gearbox synchronized, PTO revolution speed (4WD 24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . . . .
PTO revolution speed (540E rpm) synchronized with gearbox (18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . .
PTO revolution speed (540E rpm) synchronized with gearbox (24.85 mph (40 km/h) model) . . . . . . . . . . . . . . . . . .
Diameter of driven shaft at bearings . . . . . . . . . . . . . . . . . . .
Diameter of driven shaft at grooved terminal . . . . . . . . . . . .
13/8” (6 grooves) (continued)
87744428A − 11 − 2007
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
3
DATA (cont)
PTO 540/1000 rpm (optional for all models) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Engagement and Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Direction of rotation (from tractor rear) . . . . . . . . . . . . . . . . . .
same as PTO 540/540E rpm
Speed Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of hand lever located on the rear RH side of the driver’s seat
Engine speed with PTO at 540 rpm . . . . . . . . . . . . . . . . . . . .
rev/min
2196
Engine speed with PTO at 1000 rpm . . . . . . . . . . . . . . . . . . .
rev/min
2260
PTO revolution speed with engine at max. power of 2300: − for 540 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − for 1000 rpm PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
rev/min rev/min
565 1017
PTO revolution speed (540 rpm) synchronized with gearbox (18.64 and 24.85 mph (30 and 40 km/h) models) .
rev/ wheel rev
see power take off 540/540E rpm
PTO revolution speed (1000 rpm) synchronized with gearbox (18.64 mph (30 km/h) model) . . . . . . . . . . . . . . . . . .
rev/ wheel rev
28.18
PTO revolution speed (1000 rpm) synchronized with gearbox (4 WD 24.85 mph (40 km/h) model) . . . . . . . . . . . .
rev/ wheel rev
22.48
rev/min rev/min
13/8” (6 grooves) 13/8” (21 grooves)
External diameter of driven gear support bushings . . . . . . .
in. (mm)
1.8080 to 1.8090 (45.925 to 45.950)
Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.8129 to 1.8139 (46.050 to 46.075)
Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0039 to 0.0059 (0.100 to 0.150)
Diameter of driven shaft at front and central bushings . . . .
in. (mm)
1.4947 to 1.4957 (37.966 to 37.991)
Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . .
in. (mm)
1.3766 to 1.3775 (34.966 to 34.991)
Internal diameter of front and central bushings . . . . . . . . . .
in. (mm)
1.4960 to 1.4975 (38.000 to 38.039)
Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.3385 to 1.3401 (34.000 to 34.039)
Clearance between shaft and front and central bushings . .
in. (mm)
0.0003 to 0.0028 (0.009 to 0.073)
Clearance between shaft and rear bushing . . . . . . . . . . . . . .
in. (mm)
0.0003 to 0.0028 (0.009 to 0.073)
Diameter of driven shaft at grooved terminal: − 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
87744428A − 11 − 2007
4
SECTION 31 − MECHANICAL POWER TAKE−OFF − 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 380001609
Drift for PTO driving shaft roller bearings.
X 380001610
Hand grip (with 380001609).
X 380001620
Power take−off drive shaft seal splining tool (with 380001610).
X 380001611
Grooved guide for synchronized PTO shaft hub installation.
Tool to be made to remove−install the PTO shaft (Mark tool with no. 50159 − Measurements in mm) Construct in C40−(1) material CH 36 hexagonal.
1
26636
1
87744428A − 11 − 2007
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
5
TIGHTENING TORQUES
C2 − 25Nm
C1− 21Nm C − 294Nm 27853
C4 − 294Nm
C1 − 21Nm 26038
2 540 rpm power take−off
Power take−off − 540/540E rpm
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread
Bearing support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Nm
kgm
M 12 x 1.25
98
10
Self locking nuts for securing grooved terminal for PTO 540/1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 12 x 1.25
162
16.5
PTO cover retaining bolts (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
21
2
PTO guard retaining bolts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
25
2.6
Driven gear shaft locknut: (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 32 x 1.5
294
30
87744428A − 11 − 2007
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
6
2 3 4
1
5
21 21
6
17 20 19 18
13 16
11
A
27854
7
14
8 26041
10
9
B
C 3 Longitudinal sectional diagram of 540 rpm, 540/540E rpm and 540/1000 rpm PTO A. B. C. 1. 2. 3. 4. 5. 6. 7. 8. 9.
Sectional diagram of 540 rpm PTO. Sectional diagram of 540/750 rpm PTO. Detail of 540/1000 rpm PTO. 540 rpm PTO cover. 540/750 rpm PTO cover. Drive shaft bearings. Driven shaft bearings. Compression ring. 540/750 rpm grooved terminal. PTO cover retaining bolt. Rear transmission casing. Driven gears support bushings.
87744428A − 11 − 2007
10. 11. 13. 14. 16. 17. 18. 19. 20. 21. 22. 23.
Rear bearing support. 540 rpm driven gear. PTO cover retaining bolts. Nut locking driven gear shaft. Fixed gear. Grooved terminal. Coupling sleeve. 540 rpm driven gear. 750 rpm driven gear. Driving gear. Self−locking nuts for securing grooved terminal. Grooved terminal 540/1000 rpm PTO.
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
7
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 speeds, synchronized 540/540E rpm synchronized.
4
PTO controlled directly from the engine clutch Proceed as follows: −
engage the clutch by moving the control lever (1) to the horizontal position.
When engaged, the PTO grooved terminal rotates and the relevant lamp on the dashboard illuminates.
5 In these conditions PTO operation is completely independent from the tractor travel, therefore: −
halt the tractor without stopping the power take− off;
−
stop the power take−off without halting the tractor (by disengaging the power take−off clutch).
−
Disengage the PTO by moving the control lever (1) to the vertical position.
6
87744428A − 11 − 2007
8
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
PTO synchronized with gearbox (mechanically controlled models). Proceed as follows: −
disengage the clutch control lever (1, fig. 6);
−
with the tractor stationary, fully press the engine gear clutch pedal;
−
wait briefly, then move the lever (1) from position D (PTO not synchronized) to position C (PTO synchronized) and release the engine gear clutch pedal. 7
PTO synchronized with gearbox (Power− Shuttle/Dual Command (2 Speed Power Shift) models). Proceed as follows: −
disengage the clutch control lever (1, fig. 6);
−
with the tractor stationary, move the lever (1, fig. 7) to position C.
In these conditions the PTO coupling sleeve (3) is directly driven by the toothed coupling of the gearbox gear (1).
2
3
1 When the tractor is stationary, the synchronized PTO does not rotate; reverse the direction of rotation of the output shaft by moving from forward gear to reverse.
CAUTION Do not engage the synchronized PTO when the tractor is moving. Select 1000 rpm PTO for engine axle trailers.
NOTE: For models with mechanical gearboxes, when the PTO is not in use, keep the clutch lever (1, fig. 6) in the vertical position and the control lever (1, fig. 7) in position B.
87744428A − 11 − 2007
26044
8
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
9
Power take−off speed selection lever.
A
To select the PTO speed, move the lever (1) to the required position (2) and secure the lever (1) in the groove. This activates the external control lever by means of a tie−rod. The external control lever rotates the internal cam device and selects the required PTO speed by means of coupling sleeves (18, fig. 3). With the lever (1) in the central position (A), the grooved PTO terminal will not rotate (two speed PTO).
540
540E
26083
9
MECHANICAL PTO TROUBLESHOOTING Problems
Possible Causes
Solutions
Slipping with speed loss on PTO Wear of clutch disk or of engine Check the data on the appropriate pagrooved terminal. flywheel pressure plate. ges in Section 18, replace the worn Incorrect adjustment of PTO parts and adjust the clutch lever. clutch lever. Difficulty in selecting PTO speed External control stiff or incorrectly Lubricate the control cable sheath. by means of lever 1, fig. 9. adjusted. Adjust the control.
87744428A − 11 − 2007
10
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
Op. 31 112 20 MECHANICAL PTO Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows 1. Carry out operation 21 118 10 or 21 118 12 Rear transmission housing−gearbox, only removal (see Section 21, Chapter 1). 2. Remove the securing ring and extract the PTO drive shaft rear cover (1).
26046
10 3. Remove the front and rear rings (1) securing the external PTO gearbox and remove the end of the drive shaft.
26047
11 4. Remove the external PTO gear (1), through the cover opening, together with the gear control rod and final drive.
26048
12
87744428A − 11 − 2007
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
11
5. From the same opening, also remove the synchronized PTO gear (1).
26049
13 6. Remove the ring and extract the front PTO shaft (1) recovering the synchronized PTO driven gear.
1
26050
14 7. Remove the retaining pins (1) securing the control lever (2).
26051
15 8. Remove the PTO driven shaft lock nut, using the grooved wrench 50159 (1) and remove the driven shaft.
26052
16
87744428A − 11 − 2007
12
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
9. Unscrew the retaining bolts (1) from the PTO cover (2) and remove the cover by means of the internal revs selection rod.
26053
17 10. Remove the external pin (2) and extract the PTO revs selection rod (1).
26054
18 11. Remove the speed selection control cam, gears and levers from the PTO housing. 12. To re−fit the PTO, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Fit the control levers and PTO gears in their seats.
−
Fit the PTO revs selection rod and insert the rod securing pin.
−
Fit the internal revs selection rod and the PTO cover, securing in position with the bolts.
−
Fit the driven shaft in the PTO housing, tightening the driven shaft lock nut with grooved wrench 50159.
−
Fit the control lever securing pin.
87744428A − 11 − 2007
26055
19
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1 −
Insert the front PTO shaft, using the grooved guide for fitting the synchronized PTO gear shaft hub No. 380001611 (1). When the gear is in its seat, remove the grooved guide. Fit the retaining ring on the shaft.
−
Insert the driven gear and the PTO external gear from the cover hole, with gearbox command rods and final drive.
−
Insert the terminal part of the drive shaft and install the front and rear external PTO gear securing rings.
−
Install the rear drive shaft cover and the respective fastening ring.
−
Carry out operation 21 118 10 or 21 118 12 Rear transmission housing−gearbox, only installation (see Section 21, Chapter 1).
13
26056
20
87744428A − 11 − 2007
14
SECTION 31 − MECHANICAL POWER TAKE−OFF − CHAPTER 1
87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
1
SECTION 33 − BRAKING SYSTEM Chapter 1 − Brakes CONTENTS Section
Description
Page
33 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
33 202 60
Right or left−hand brake. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
33 202 46
Braking system hydraulic pump. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
33 110 40
Parking brake. Brake disks. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
33 110 08
Handbrake control. Travel adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
DATA Type: −
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with oil bath disk, acting on differential drive shafts
−
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with oil bath disks, engaging a gear on the bevel pinion shaft
Control: −
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
hydrostatic, with independent pedals (connected by means of a pin)
−
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
mechanical, by means of a hand lever
Service brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . .
sintered
Parking brake disk material . . . . . . . . . . . . . . . . . . . . . . . . . .
steel
Parking brake mobile sectors material . . . . . . . . . . . . . . . . .
sintered or organic agglomerate
Disk thickness: −
service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.3937 (10)
−
wear limit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.3385 (8.6)
−
parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.1555 to 0.1594 (3.95 to 4.05) (continued)
87744428A − 11 − 2007
2
SECTION 33 − BRAKING SYSTEM − CHAPTER 1 DATA (cont)
Parking brake friction disk thickness (mobile sectors): −
lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.1220 to 0.1338 (3.1 to 3.4)
−
intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.1653 to 0.1771 (4.2 to 4.5)
Hydrostatic control Hydraulic pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Working pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with 2 master cylinders independently operated by brake pedals psi (bar)
255.2 (17.6)
Control pedal adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 14
Bleeding air from brake circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
see page 15
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
Nut securing final drive to transmission casing (C1) . . . . . . . . . . .
−
Guide bolts for parking brake mobile sector (C2) (:) . . . . . . . . . .
−
kgm
135 to 149 13.8 to 15.2 24
2.5
(:) Apply 2 drops of LOCTITE 243 thread lock.
C1 −135:149 Nm
C 2−24 Nm 26057
26058
1
87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
8
9
1
3
2
60x95x23
26059
X
3
7
6
26060
5
4 2 Service brake and parking brake sectional drawings
1. 2. 3. 4. 5.
Service brake disk. Final drive casing spacer. Parking brake disks. Braking sectors. Parking brake internal control lever.
6. 7. 8. 9.
Parking brake support. Seals. Brake drive piston. Guide grub screw.
NOTE: On assembly apply a bead of sealing compound to the surfaces X as indicated on page 10.
87744428A − 11 − 2007
4
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
1
2
3
4
5
26062
3 Front axle brake diagram 1. 2. 3.
Brake drive piston. Brake wear disk. Guide pin.
87744428A − 11 − 2007
4. 5.
Brake disk. Seals.
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
5
24664
4 Service brake sectional drawing 1. 2. 3.
Spring. Pump body. Control piston.
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
4. 5. 6.
Rear seal. Central seal. Front seals.
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.
24663
5 Tool to be made for disassembly−assembly of the final drives, to be used with 50114. (Mark part with No. 50091 − Measurements in mm) Construct in Aq 42 D − 1 material. Make 2 tie−rods in C 40 bon material.
87744428A − 11 − 2007
6
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
26258
6 Tool to be made for removal−installation of the final drives, to be used with a part of 50091. (Mark part with No. 50114 − Measurements in mm) Construct in Fe 42 C material − (*) Define measurement according to the hydraulic jack seat.
DESCRIPTION AND OPERATION SERVICE BRAKES The service brakes are hydraulically operated with oil bath disks. The two control pumps (one for each pedal) are located in the front part of the cab and are connected to their respective pedals by means of two tie−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 disks are not equally worn. The two control pumps are fed from a single reservoir positioned above the pumps.
87744428A − 11 − 2007
The brake disks (one for each rear wheel) are located between the rear transmission casing and the final drive casing. The disks are splined on the differential drive shafts.
PARKING BRAKE The parking brake is mechanically operated, by means of an intermediate gear on the rear bevel pinion shaft, and is controlled by a lever located on the left−hand side of the operator. When the parking brake control lever is applied, the tie−rod acts on the external support lever and moves the braking sectors up against the three brake disks splined to the intermediate gear, thereby stopping the tractor.
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
7
BRAKE TROUBLESHOOTING Problems Brake pedals hard to operate.
Possible Causes
Solutions
1. Corresponding master cylin- Replace the brake control pump. 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.
Braking noisy.
1. Friction material on brake Replace the brake disks. disks worn (1, fig. 2).
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. Incorrect tyre pressure.
Inflate the tyres to the correct pressure.
2. Brake control pumps worn.
Replace the brake control pumps.
Unbalanced braking.
3. Pump connection pipes ob- Clean or replace the pipes. structed or pinched. 4. Brake control pipes structed or pinched.
ob- Clean or replace the control pipes.
5. Pump control piston seals Replace the brake control pumps. worn or damaged. 6. Friction material on brake Replace disk. disks worn (1, fig. 2). (continued)
87744428A − 11 − 2007
8
SECTION 33 − BRAKING SYSTEM − CHAPTER 1 BRAKE TROUBLESHOOTING (cont)
Problems Inefficient braking.
Possible Causes
Solutions
1. Friction material on brake Replace the brake disks. disks worn (1, fig. 2). 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 incorrectly ad- Adjust correctly. justed. 2. Braking fig. 2).
sectors
The tractor remains braked when 1. Control return structed. the parking brake is disengaged.
worn
stroke
(4, Replace the braking sectors.
ob- Remove obstructions.
2. Braking sectors (4, fig. 2) se- Release and replace damaged parts. ized on brake disks.
87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
9
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. Check that no one is in the vicinity of the load to be lifted. 26063
Proceed as follows.
7
1. Carry out operation 27 120 10 or 27 120 20 Right or left−hand final drive casing, only removal (see Section 27, Chapter 1). 2. Remove the brake disk (1) from the seat in the transmission casing (2) and recover the control piston. 3. To refit the right or left−hand brake, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Check the control piston seals and replace, if necessary.
−
Fit the control piston (1) in the seat in the rear transmission casing (2), using a rubber mallet.
−
Fit the brake disk (1, fig. 7).
−
Carry out operation 27 120 10 or 27 120 20 Right or left−hand final drive casing, only installation (see Section 27, Chapter 1).
26064
8
87744428A − 11 − 2007
10
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
26254
9 Diagram of seal compound application for brake assembly and final drives on the transmission casing The types of sealing compound are listed on page 1, Section 00.
87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
11
Op. 33 202 46 BRAKE HYDRAULIC PUMP Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows to remove the hydraulic pump. 1. Block the wheels using chocks. 2. Carry out operation 90 100 22 Bonnet opening, only removal (see Section 90). 3. Carry out operation 90 100 84 Bonnet guard, only removal (see Section 90). 4. Carry out operation 41 204 10 Hydrostatic steering wheel, only removal (see Section 41, Chapter 1). 5. Carry out operation 55 418 10 Multi−indicator panel, only removal (see Section 55, Chapter 7). 6. Remove the instrument panel upper guard retaining bolts (1). 10 7. Remove the steering column dust guard (1).
11 8. Loosen the screw and detach the hand throttle control lever grip (1).
12
87744428A − 11 − 2007
12
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
9. Remove the fuse box cover (1), unscrew the retaining screws and remove the fuse box.
13 10. Unscrew the indicator lights switch ring nut (1).
14 11. Unscrew the retaining screw and remove the lights switch knob (1).
15 12. Unscrew the lights switch locknut (1) and the starter ring nut (2).
16 87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
13
13. Remove all the electrical connections and remove the instrument panel upper guard (1).
17 14. Unscrew the retaining bolts and remove the lower guard (1). (Carry out this operation on both sides).
18 15. Remove the spring (1) and extract the pin (2) to free the brake pedal. (On both brake pedals).
19 16. Disconnect the brake pump pressure switch connection (1).
20
87744428A − 11 − 2007
14
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
17. Disconnect the brake piping (2), remove the pump connection pipe.
21 18. Disconnect the brake pump piping (1) and attach to the reservoir, to avoid spilling the oil inside.
22 19. Unscrew the retaining bolts and remove the brake pump (1). Repeat operations for the other brake pump. 20. To re−fit the brake pumps, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Position the brake pumps and secure.
−
Connect the pump infeed piping.
−
Attach the pump connection pipe.
−
Connect the brake piping.
−
Connect the pressure switch.
−
Connect the brake pumps to the control pedals.
−
Fit the two lower guards.
87744428A − 11 − 2007
23
SECTION 33 − BRAKING SYSTEM − CHAPTER 1 −
Connect the electrical connections and position the upper guard.
−
Tighten: the starter and lights switch ring nuts.
−
Assemble and secure the lights switch knob.
− − − −
15
−
Fit the upper guards.
−
Carry out operation 55 418 10 Multi−indicator panel, only installation (see Section 55, Chapter 7).
Tighten the indicator lights switch ring nut.
−
Carry out operation 41 204 10 Hydrostatic steering wheel, only installation (see Section 41).
Position the fuse box, secure in position and fit the cover.
−
Carry out operation 90 100 84 Bonnet guard, only installation (see Section 90).
Assemble and secure the handgrip on the throttle lever.
−
Carry out operation 90 100 22 Bonnet, only installation (see Section 90).
Fit the hood on the steering column.
87744428A − 11 − 2007
16
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
Service brakes control pedals stroke adjustment.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
Proceed as follows. 21. With the brake pedals mounted and connected to the relative pumps, and the spring connected, check that the pin (1) enters the hole on the left− hand pedal without obstructions. 22. If interference is detected, disconnect the spring from the lower pedal, adjust the fork (1) in order to eliminate the pin interference, then tighten the locknut. Connect the spring.
24
25
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 right−hand (2) and the left−hand (1) brake reservoirs are 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.
87744428A − 11 − 2007
26
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
17
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 pedals 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. 27
8. On completion of the operation, top up the oil level in the reservoir. 9. Thoroughly clean the external parts of the assemblies near the bleeding screws (1) and (2). 10. Push the left−hand brake pedal down, slowly and fully, so that the oil is put in pressure. 11. Keep the pedal pressed down, unscrew the bleeding screw (1) by half a turn, allowing the oil/ air bubble mixture to flow out. 12. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 13. Press the brake pedals again to put the circuit under pressure, i.e.: when the pedal travel returns to normal.
28
14. Repeat the aforementioned operation on the brake circuit screw (2). 15. On completion of the operation, top up the oil level in the reservoir. 16. Remove the cap (1). 17. Connect the brake pedals by means of the pin and push both brake pedals down, slowly and fully, so that the oil is put in pressure.
26457
29
87744428A − 11 − 2007
18
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
18. Keep the pedal pressed down, unscrew the bleeding screw (1), located inside the front final drive, by half a turn, allowing the oil/air bubble mixture to flow out. 19. Tighten the screw (1) and repeat the aforementioned operation until oil without air bubbles flows out. 20. Press the brake pedals again to put the circuit under pressure, i.e.: when the pedal travel returns to normal. 21. Repeat the aforementioned operation on the right−hand part of the brake circuit.
26583
30
22. On completion of the operation, top up the oil level in the reservoir and tighten the caps (1).
NOTE: To match the front brake bleed screw (1) fig. 30 with the front side final drive plug (1) fig. 29 place the latter in the vertical position.
NOTE: On tractors fitted with trailer brake valves, after bleeding operations on rear and front brakes, bleed the valve using the screw (1) in the manner previously described.
27633
31
87744428A − 11 − 2007
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
19
Op. 33 110 40 − 33 110 44 PARKING BRAKE Removal − Installation Parking brake disks
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
To remove the parking brake disks, proceed as follows. 1. Unscrew the cap and drain the oil from the rear transmission casing (the prescribed quantity is 11.09 US gal. (42 litres)). 25628
32 2. If fitted, carry out operation 33 220 40 Trailer brake valve, only removal (see Section 35, Chapter 3). 3. Unscrew the four retaining bolts (1) and remove the parking brake disks access guard (2).
1
26078
33 4. Remove the safety ring (1) from the parking brake disks (2).
26080
34
87744428A − 11 − 2007
20
SECTION 33 − BRAKING SYSTEM − CHAPTER 1
5. Recover the safety ring (1), the brake disks (2) and the friction disks (3). 6. To refit the parking brake disks, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Follow the illustrations in fig. 2 for the positioning of the various parts.
−
Insert the brake disks and friction disks in their respective seats.
−
Fit the safety ring.
−
Fit the access guard on the transmission casing and secure with the four bolts.
−
If fitted, carry out operation 33 220 40 Trailer brake valve, only installation (see Section 35, Chapter 3).
−
Tighten the cap on the rear transmission casing and fill up with oil (for products and quantities see Section 00, page 6).
26081
35
Op. 33 110 08 HANDBRAKE CONTROL Stroke adjustment The parking brake lever must be adjusted whenever service operations are carried out on the assembly, and if the lever is not positioned in the third notch when the brake is engaged. Proceed as follows. 1. Turn the adjusting device (1) clockwise if the parking brake lever has moved more than three notches when the brake was engaged. 2. Check that the parking brake lever moves three notches on the toothed sector when the brake is engaged. 3. Check that the dashboard warning light (parking brake engaged light) illuminates when the brake lever is engaged.
36
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
1
SECTION 35 − HYDRAULIC SYSTEMS Chapter 1 − Rear mechanical hydraulic lift CONTENTS Operation
Description
Page
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Cross−sectional drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 35 110 30
Rear hydraulic lift. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . see page 19 Chapter 4
35 110 40
Lift internal controls. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lift adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
35 110 08
Tie−rod adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Various adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
35 110 42
Lift cylinder and arms shaft. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
35 114 14
Lift control valve (with control valve removed). Disassembly − Assembly . . . . . . . . . . . . . 36
35 114 30
Lift pressure relief valve. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
35 114 32
Lift pressure relief valve (Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
REAR MECHANICAL HYDRAULIC LIFT DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
with controlled position/draft and mixed control
Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of two independent levers
Setting speed of lift reaction . . . . . . . . . . . . . . . . . . . . . . . . .
automatic, by means of hydraulic device integral to control valve
LIFT−O−MATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
allows fast lifting/lowering operations using push buttons, without using the draft control position levers
Single−acting cylinder: −
rated diameter and stroke: . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
3.7401 x 5.0393 (95 x 128)
capacity: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in3 (cm3)
35.7085 (907)
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . .
psi (bar)
2755 to 2827.5 (190 to 195)
Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . .
psi (bar)
3045 to 3117.5 (210 to 215)
Lift piston diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
3.7393 to 3.7401 (94.980 to 95.000)
Internal diameter of cylinder liner: . . . . . . . . . . . . . . . . . . . . .
in. (mm)
3.7415 to 3.7429 (95.036 to 95.071)
Clearance between piston and liner . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0014 to 0.0035 (0.036 to 0.091)
−
(continued)
87744428A − 11 − 2007
2
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 REAR MECHANICAL HYDRAULIC LIFT DATA (cont)
Diameter of arm lifting shaft (5, fig. 4) at bushings: −
right−hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
2.1641 to 2.1653 (54.970 to 55.000)
−
left−hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.8887 to 1.8897 (47.975 to 48.000)
Internal diameter of bushings fitted on lift body: −
right−hand side (4, fig. 4) . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
2.1692 to 2.1725 (55.100 to 55.184) (1)
−
left−hand side (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.8936 to 1.8970 (48.100 to 48.184) (1)
Clearance between lifting arm shaft and relative right−hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0039 to 0.0084 (0.100 to 0.214)
Clearance between lifting arm shaft and relative left−hand side bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm)
0.0039 to 0.0082 (0.100 to 0.209)
Interference between bushings and relative seats . . . . . . .
in. (mm)
0.0025 to 0.0063 (0.065 to 0.161)
Axial clearance of shaft complete with lift arms . . . . . . . . .
in. (mm)
0.0078 to 0.0551 (0.2 to 1.4)
External diameter of draft control idler shaft . . . . . . . . . . . .
in. (mm)
0.8648 to 0.8661 (21.967 to 22.000)
Internal diameter of seats in support . . . . . . . . . . . . . . . . . .
in. (mm)
0.8669 to 0.8689 (22.020 to 22.072)
Clearance between idler shaft and its seat . . . . . . . . . . . . .
in. (mm)
0.0007 to 0.0041 (0.020 to 0.105)
Diameter of position control idler shaft . . . . . . . . . . . . . . . . .
in. (mm)
0.5501 to 0.5511 (13.973 to 14.000)
Internal diameter of position control idler shaft . . . . . . . . . .
in. (mm)
0.5518 to 0.5535 (14.016 to 14.059)
Clearance between draft control idler shaft and position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0006 to 0.0033 (0.016 to 0.086)
Clearance between control valve block pin (8, fig. 9) and the relative seat on the control valve block body . . . . . . . .
in. (mm)
0.0003 to 0.0004 (0.008 to 0.012) (2)
Clearance between lift control valve (9) and the relative seat on the control valve block body . . . . . . . . . . . . . . . . . .
in. (mm)
0.0003 to 0.0005 (0.008 to 0.014) (2)
Check valve return spring (3, fig. 9): −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.0039 (25.5)
−
spring length under load of 52 to 56 N (5.28 to 5.72 kg) in. (mm)
0.6889 (17.5)
Control valve block pin return spring (5, fig. 9): −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
spring length under load of 31.7 to 35 N (3.23 to 3.57 kg) in. (mm)
in. (mm)
1.9881 (50.5) 1.3385 (34)
Control valve return spring (10, fig. 9) −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.7322 (44)
−
spring length under load of 103 to114.7 N (10.5 to 11.7 kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.1417 (29)
Arm descent speed control valve spring (13, fig. 9) −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.3385 (34)
−
spring length under load of 67 to 73 N (6.86 to 7.46 kg) in. (mm)
1.0629 (27)
Intervention speed control valve spring (11, fig. 9): −
spring free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
−
spring length under load of 65 to 71 N (1.61 to 1.79 kg) in. (mm)
0.5708 (14.5) 0.433 (11)
(1) Value to be obtained after obtaining interference fit without grinding operations. (2) During assembly the control valve block pins and control valves are carefully selected so as to obtain the required clearance.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
3
IMPLEMENT HITCHING DEVICE DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
three−point linkage 1st and 2nd
Category: Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by means of lower arms with flex bar
Maximum lifting load from horizontal arm link ends with three−point linkage connected to upper hole on top link and full length of lifting stroke . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lbs. (kg)
5822.84 (2640)
Maximum lifting load with centre of gravity 24.01 in. (610 mm) from the lower arm link ends for the full length of lifting stroke (with top link connected to upper hole on support): . . . . . . . . . . . . Flex bar diameter: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
lbs. (kg) in. (mm)
5061.9 (2295) 0.979 to 0.9803 (24.867 to 24.9)
End float of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.059 to 0.2133 (1.5 to 5.42)
TIGHTENING TORQUES Tightening torque Nm kgm
PARTS TO BE TIGHTENED
Thread
Lift Lift intervention speed adjustment valve cap (C1, fig. 1) . . . . . . . . . . .
−
54
5.5
Control valve block pin spring cap (C2) . . . . . . . . . . . . . . . . . . . . . . . . .
−
54
5.5
Bolts securing control valve block to lift (C3) . . . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
26
2.7
Bolts securing union to control valve block (C4) . . . . . . . . . . . . . . . . . .
−
44
4.5
Check valve union (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 24 x 1.5
83
8.5
Cylinder safety valve (C6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
83
8.5
Control valve cap (C7) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
54
5.5
Lift cylinder retaining bolts: − front (C8) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − top (C10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 x 1.5 M 16 x 1.5
157 260
16 26.5
Bolts securing lift to rear transmission housing (C9) . . . . . . . . . . . . . . M 12 x 1.25
98
10
Control lever quadrant cover stud bolts (C11) . . . . . . . . . . . . . . . . . . . .
−
49
5
Nuts for lever quadrant cover stud bolts (C12) . . . . . . . . . . . . . . . . . . .
M 8 x 1.25
25
2.6
LIFT−O−MATIC control lever quadrant retaining nut (C13) . . . . . . . . .
−
54
5.5
Lifting arm plate retaining bolts (C14) . . . . . . . . . . . . . . . . . . . . . . . . . . .
M 14 x 1.5
142
14.5
Eccentric pin retaining nut (C15) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
49
5
Eccentric pin seat cap (C16) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
83
8.5
LIFT−O−MATIC control lever retaining bolts (C17) . . . . . . . . . . . . . . . .
−
54
5.5
Quadrant with arms control pivot cam retaining bolts (C18) . . . . . . . .
−
49
5
Internal lever mechanisms support pin (C19) . . . . . . . . . . . . . . . . . . . .
−
54
5.5
Flex bar seal support retaining bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . .
−
64
6.5
Lateral stabiliser strut support retaining bolts . . . . . . . . . . . . . . . . . . . .
M 16 x 1.5
221
22.5
Pick−up hitch hook support retaining bolts . . . . . . . . . . . . . . . . . . . . . .
M 16 x 1.5
221
22.5
Implement hitching device
87744428A − 11 − 2007
4
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
C1
C2
TIGHTENING TORQUES
C3
C4
C5 25428
25427
C3
C6
1 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 HYDRAULIC LIFT TOOLS
X 380000260
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 380000230
380000224 380000301 X 380001627 X 380001628 X 380000261
X 380000260 X 380000260
Hydraulic lift lifting hook. Rotating stand for overhaul operations. Ring for fitting piston with lift seals. Punch for fitting lift arm shaft seal. Punch for fitting needle bearings on control valve block control lever bushing. Punch for fitting needle bearings on lower draft control lever. Punch for fitting needle bearings on upper draft control lever.
X 380000231 X 380001629 380000240 380000215 X 380000218 X 380000217 X 380000274 X 380000275 X 380001630 X 380001631
5
Punch for fitting needle bearings on draft control link rod. Wrench for cylinder safety valve setting ring nut. Wrench for lift pressure relief valve setting ring nut. Guard for fitting seal on arm descent speed control pin. Universal pressure control kit. Hand pump for valve calibration. Union for cylinder safety valve calibration. Union for lift pressure relief valve calibration. Union for checking control valve seal. Guard for pilot valve seal. Draft control setting tool. Position and draft control setting tool.
(*)
26626
2 Bracket to be made for hook 291359 or for overhauling lift to rotating stand (mark tool No. 50155 − measurements in mm). Make in Aq 42 material − (*) Area for fixing bore to rotating stand.
87744428A − 11 − 2007
6
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
*
27860
3 Adapter to use with hook 291359 (mark tool No. 50163 − Measurements in mm). Make in Fe 42 C material
Note* (See tool no. 50155)
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
7
4 1. 2. 3. 4. 5. 6. 7.
Cross−sectional view of lift arms drive shaft Right−hand arm. 8. Left−hand arm thrust washer. Right−hand arm thrust washer. 9. Left−hand arm. Right−hand seal. 10. Internal arm. Right−hand bush shaft support (5). 11. Eccentric control position. Lift arm control shaft. 12. LIFT−O−MATIC control pin. Left−hand bush shaft support (5). 13. LIFT−O−MATIC control external gear mechanism. Left−hand seal.
5 1. 2.
Longitudinal cross−sectional view of lift Cylinder liner. 3. Lifting piston. Control valve block/cylinder connecting pipes.
87744428A − 11 − 2007
8
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
6 1. 2. 3. 4. 5.
Longitudinal and cross−sectional views of lift Anti−extrusion seal and ring. 6. Lever mechanism unit in operation with controlled position. Control valve block arm lever pin. 7. Lever mechanism unit in operation with controlled Control valve block arm lever. position. Draft control transmission shaft. Position control transmission shaft.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
9
25438
7 1. 2. 3.
Longitudinal and cross−sectional views of lift Control valve block pin. 4. LIFT−O−MATIC device spring. Control valve block lever pin. 5. LIFT−O−MATIC lever control pin. Contact ball joint between control valve block pin (1) 6. LIFT−O−MATIC external control lever. and control lever (2).
87744428A − 11 − 2007
10
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
8 Draft control device cross−sectional views 3. Draft transmission rod. C1. Spacer ring and lower lift arm retaining bolt. 4. Flex bar. G = 0.0590 to 0.2133 in. (1.5 to 5.42 mm). Axial clearance of flex bar. 5. Spacer. 1. Lever mechanism unit in operation with controlled 6. Seal. draft. 7. Ball bushing. 2. Lift adjustment rod in draft control operation. 8. Draft transmission lever.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
11
1
14
2
13
3
4 25443
12
5
6 11
25444
7 10
9
8 9
1. 2. 3. 4. 5. 6. 7.
Hydraulic lift control valve block cross−sectional views Oil infeed union. 8. Control valve block pin. Check valve ball. 9. Control valve. Check valve return spring. 10. Control valve return spring. Cylinder safety valve. 11. Intervention speed adjustment valve spring. Control valve block pin return spring. 12. Intervention speed adjustment valve. Seal and ring. 13. Arm descent speed adjustment valve spring. Control valve block pin seat. 14. Seal and ring.
NOTE: When fitting seals 6 and 14, heat the corresponding support disks in oil at a temperature of approximately 122 °F (50 °C). When fitting seal (14) and its support disk, use protection device 380001629. When fitting seal (6) and its support disk, use protection device 380000275.
87744428A − 11 − 2007
12
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 DESCRIPTION AND OPERATION
The mechanical lift can operate with controlled position and draft, and with mixed control. The lift is controlled by two special levers located on the operator’s right−hand side. It also features the Lift−O−Matic device which raises and lowers the implement without having to use.
Draft control is performed by the flex bar, positioned in the seat mounted in the rear transmission housing the position and draft control levers. The lower lift arms and corresponding control rods are connected to the flex bar.
4 1
2
3 5
6 27898
Oil at static rest
Discharge oil
Intake oil
Brake circuit oil at rest
Delivery oil
10 HYDRAULIC LIFT CIRCUIT 1. 2. 3.
Hydraulic pump. Pressure relief valve. Trailer brake valve.
87744428A − 11 − 2007
4. 5. 6.
Rear auxiliary control valves. Lift hydraulic control valve. Filter.
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
13
1
7
2 3 6
4
5 26625
Discharge oil Pressurized oil 25445
A 11
D. 1. 2. 3.
Detail of control position operation. Intervention speed adjustment valve. Arm descent speed control valve. Cylinder safety valve.
ARM LIFT PHASE 4. Non−return valve. 5. Draft transmission rod. 6. Control valve block pin. 7. Control valve.
When the operator uses the position control lever (located on the right−hand side) to raise the arms, the movement shown by the arrows (detail a) is transmitted by the internal lever mechanisms to the control valve block pin (6). This pin interrupts the oil flow to the control valve (7), which is pulled by its spring.
The pressurised oil opens the check valve (4) and pushes on the arm lifting piston. With controlled draft operation, the lift command is sent to the flex bar, which in turn transmits the movement (shown by the arrows) to the control valve block pin (6) via the transmission rod (5).
87744428A − 11 − 2007
14
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
1
7
2 3 6
4
5
26624
Oil at static rest Discharge oil Delivery oil
26678
12 NEUTRAL PHASE 1. 2. 3. 4.
Intervention speed adjustment valve. Arm descent speed control valve. Cylinder safety valve. Non−return valve.
When the lift arms have reached the predetermined height, the internal lever mechanisms are stationary. The position of the control valve block pin (6) directs the oil to the control valve piston (7). The oil pressure
87744428A − 11 − 2007
5. 6. 7.
Draft transmission rod. Control valve block pin. Control valve.
on the control valve piston overcomes the resistance of the spring and moves the valve. This creates a discharge opening and allows the oil to flow to the transmission casing instead of the lift cylinder.
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
15
Discharge oil Delivery oil
1
7 2
3 6 4
5 26623 26676
A 13
ARM LOWER PHASE A. 1. 2. 3.
Control position operation. Intervention speed adjustment valve. Arm descent speed control valve. Non−return valve.
When the operator lowers the position control lever on the right−hand side, the arms are lowered. The internal lever mechanisms transmit movement (shown by the arrows, detail a) to the control valve block pin (6). The control valve block pin (6), is pulled downward by its spring, allowing the cylinder of oil, under the thrust of the piston, to discharge through the arm descent speed control valve (2) and the outlet created by the control valve block pin. The discharge oil passes through the valve (2) and pushes on the control valve piston (7). This overcomes the resistance of the spring and moves the valve, thereby creating an outlet and allowing the oil to flow to the transmission housing instead of the lift cylinder.
4. 5. 6. 7.
Draft transmission rod. Control valve block pin. Control valve. Cylinder safety valve.
With controlled draft operation, the lowering command is sent to the flex bar, which in turn transmits the movement (shown by the arrows) to the control valve block pin (6) via the transmission rod (5). NOTE: The lowering speed of the implement connected to the lift arms is controlled by the position of the arm descent speed control valve (2). Unscrewing the valve (2) control screw reduces the size of the outlet between the valve and the control valve block body: the implement takes longer to come down. Fully tightening the screw increases the size of the discharge opening and the implement lowers faster.
87744428A − 11 − 2007
16
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 HYDRAULIC LIFT TROUBLESHOOTING
Problems
The lift does not rise.
Possible Causes
1. Clogged oil filter.
Solutions
Replace filter.
2. Control valve jammed in di- Release control valve. scharge position.
The lift moves in jerks.
The lift rises too slowly.
3. Hydraulic pump faulty.
Overhaul or replace pump.
1. Clogged oil filter.
Replace filter.
2. Air in the pump suction line.
Check that the unions are airtight and the seals are efficient.
1. Clogged oil filter.
Replace filter.
2. Oil leaking past the seals re- Replace all defective seals. sulting in pressure loss: piston seals or delivery union seals.
3. Hydraulic pump faulty.
Overhaul or replace pump.
The lift lowers too slowly.
1. Arm descent speed set incor- Set correctly. rectly.
The lift lowers too quickly.
1. Arm descent speed set incor- Set correctly. rectly. (continued)
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
17
HYDRAULIC LIFT TROUBLESHOOTING (cont)
Problems
Possible Causes
Solutions
Dismantle, check and replace the The lift is unable to keep the load 1. Faulty seal on check valve. parts concerned, if necessary. raised (with the engine running, the load moves up and down rhythmically; with the engine turned off, the load lowers). 2. Oil leaking past the seals on Replace seals. the control valve block pin seat.
3. Control valve block pin seal Dismantle and clean the seal; faulty. replace the control valve block pin and seat if defective.
4. Oil seeping past the lift piston Replace seals. seal or the seals on the cylinder oil discharge fitting.
5. Defective seal or cylinder sa- Replace the valve. fety valve set very low.
The pressure relief valve cuts in when the lift arms reach the completely raised position.
1. Lift arm travel set incorrectly.
Set correctly.
Lift has poor lifting capacity.
1. Pressure relief valve set incor- Replace the valve. rectly.
2. Cylinder safety valve set in- Replace the valve. correctly.
3. Poor pump efficiency (gene- Overhaul or replace pump. rally combined with a considerable increase in lift time).
87744428A − 11 − 2007
18
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
OP. 35 110 40 LIFT INTERNAL CONTROLS DISASSEMBLY−ASSEMBLY (With the lift removed)
DANGER Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
1 Proceed as follows.
2
1. Position the lift on a rotating stand 380000301 using the bracket 50155 to be made in the workshop (see fig. 2). 2. Disconnect the connecting pipe (2) between the auxiliary control valve block (1) and the lift control valve block, unscrew the retaining bolts and remove the auxiliary control valve block (1), recovering the O−Ring seal.
25453
14 3. Unscrew the retaining bolts and remove the lift hydraulic control valve block (1).
1
4. Rotate the lift holding the relative arms.
25454
15 5. Using a magnetic flexible tool (1) recover the control valve block pin contact ball (2) making sure that it doesn’t drop.
1
2
25455
16
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 6. Remove the front bolts, the rear union and recover the oil delivery pipe (1) to the lift cylinder.
19
1
25456
17 7. Unscrew the retaining bolts and remove the Lift− O−Matic device spring (1).
1
25457
18 8. Unscrew the retaining bolts (1), loosen and remove the pin (2) and bush, then recover the control valve block lever mechanisms (3).
1
9. Unscrew the cylinder retaining bolts and remove.
3
2 25458
19 10. Unscrew the retaining nuts and recover the support cap (1) and spring.
1
NOTE: Apply pressure on the support (1) to prevent the spring from pressing it against the retaining nut.
25461
20
87744428A − 11 − 2007
20
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
11. Unscrew and remove the draft control internal lever pivot eccentric pin (1).
1
25462
21 12. Remove the circlip (4) and recover the washer, the external lever (3), the relative clutch disks, the Woodruff key and extract the draft and position control internal levers (1 and 2) and shafts from the inside.
1
2 3
4 25463
22 13. Using the drift 380000260 (1), replace the draft control internal lever (2) bearings.
1
2
14. Using the drift 380000261, replace the control valve lever bearings.
26298
23
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
21
Assembly
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
15. To re−fit the hydraulic lift internal controls, proceed as follows. −
Study the illustrations in figs. 4, 5, 6, 7 and 8 for the positioning of the various parts.
−
Apply the torque settings listed on page 3.
−
Fit the position and draft control internal levers, complete with: shafts, keys, clutch disks, external levers, washers and circlip.
−
Tighten the draft control internal lever pivot eccentric pin.
−
Fit the spring and cover on the position and draft control axis and secure the cover with the lock nuts.
−
Fit the control valve block control lever unit.
−
Fit the cylinder.
−
Fit the Lift−O−Matic device spring.
−
Fit the oil delivery pipe to the lift control cylinder.
−
Fit the control valve pin contact ball.
Carry out the adjustments described below. NOTE: The adjustments must be carried out in the order specified. −
Carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 0.0787 in. (2 mm)) along the marked line shown in the drawing. The types of sealing compound are listed on page 1, Section 00. Fit the hydraulic lift on the lift box and secure in position with the relative retaining bolts. 27156
−
Fit the auxiliary control valve block, the O−Ring seals and the connecting pipe to the lift hydraulic control valve block.
24
87744428A − 11 − 2007
22
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
LIFT ADJUSTMENTS The following adjustments refer to a lift assembly without hydraulic control valve block and mounted on a rotary stand.
1
NOTE: These adjustments must be carried out in the order specified. 16. Detach the spring (1) in order to exclude the Lift− O−Matic device.
25470
25 Adjusting controlled position Proceed as follows. 17. Move the external position control lever (2) completely forward against the spacer for the stud bolt securing the spring retaining bracket, and the external draft control lever (1) completely back against the spacer. 18. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
1
2 25471
26 19. Position the contact ball (3, fig. 7) in its seat and attach tool 380001631 (1) to the lift body so that it makes contact with the ball.
1
Rotate the lift through 180° holding the arms.
25472
27 20. Loosen the locknut and totally unscrew the adjustment bolt (2), to the end of the lever (1).
1
NOTE: To facilitate this operation, lower the lift arms. Once the operation has been completed, return the lift arms to their original position.
2
25473
28 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 21. Unscrew the locknut (1) and tighten or slacken the rod (2).
23
1
2
25474
29 22. Check that the cap end (2) of the tool 380001631 (1) is at exactly the same external stop face as the tool. Tighten the locknut (1, fig. 29).
1
2 25475
30 23. Move the external position control (1) and draft control (2) levers completely backwards against the spacer.
1
2
25476
31 24. With the lift arms fully lowered, check that the cap (2) of tool 380001631 (1) is either aligned with or further inside than the internal reference surface on the tool (1).
1
2 25477
32 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
24
Upper stroke limit adjustment Proceed as follows. 25. Move the external position control lever (2) completely forward against the spacer for the stud bolt securing the spring retaining bracket, and the external draft control lever (1) completely back against the spacer. 26. Turn the arm control shaft so that the internal arm comes into contact with the lift body.
1
2 25471
33 27. Position the contact ball (3, fig. 7) in its seat and attach tool 380001631 (1) to the lift body so that it makes contact with the ball.
1
Rotate the lift through 180°.
25472
34 28. Tighten the adjustment bolt (2) on the lever (1) until the cap (2, fig. 36) of tool 380001631 (1, fig. 36) is aligned with the internal reference surface of the tool.
1
NOTE: To facilitate this adjustment bolt (2) tightening operation, lower the lift arms, then return the lift arms to their original position to check the position of the cap (2, fig. 36) on the tool.
2
Lock in position using the locknut. 25473
35
1
2 25477
36 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
25
Adjusting draft control Proceed as follows.
1 29. Move the external position control (1) and draft control (2) levers completely backwards against the spacer.
2
25476
37 30. Make sure that the milling on the eccentric pin (1) is in the vertical position.
1
25478
38 31. Place the tool 380001630 (2), complete with the end section (3) and the draft transmission rod, on a reference plane. Adjust the end section (3) until the rod on tool (1) is aligned with the tool, providing a micrometer (1) reading of 0.
1
2 3 25479
39 32. Place the tool (2) on the lift body, secure in position with the two bolts and fully tighten the screw (1).
1
2
3 25480
40 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
26
33. Adjust the draft control rod (3, fig. 40) until the end of the cap (2, fig. 41) on tool 380001631 (1) is exactly aligned with, or as near as is possible, to the external reference surface as the tool. 34. Remove tools 380001631 and 380001630 from the lift body, fit the hydraulic control valve block and attach the Lift−O−Matic device spring (1, fig. 25). Fit the lift on the tractor as follows.
1
2 25475
41 WARNING − First position tool 380001630 (2) on a reference surface and use a micrometer depth gauge (1) to measure the distance (L5) between the point where the tool rests on the reference surface and the point where the micrometer gauge rests on the tool. Mark the measured distance (L5) on the tool.
1 2
L5
25481
42 35. Fit the complete draft measuring device (3), but without the flex bar, on the rear transmission housing. 36. Rest the transmission lever (3) on the transmission casing and fit tool 380001630 (1) on this housing. 37. Use a micrometer depth gauge (2) to measure the distance (L8) between the top end of the rod (3) and the point where the micrometer gauge rests on the tool 380001630 (1).
1
2
L8 L6 3 25482
43 NOTE: The distance (L6) the top end of the rod (3) protrudes from the transmission casing (with flex bar removed) is given by: L6 = L5 − L8 where: L5 and L6 = measurements taken with tool 380001630 fitted on the reference surface (L5, fig. 42) or on the transmission housing (L8).
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 38. Fit the flex bar in the seat on the rear transmission casing and, using the micrometer depth gauge (2), measure the distance (L9) between the top end of the rod (3) and the point where the micrometer gauge rests on the tool 380001630 (1).
27
1 2 L7
L9 3
NOTE: The distance (L7) the top end of the rod (3) protrudes from the transmission casing (with flex bar fitted) is given by: L7 = L5 − L9
4 25483
44
where: L5 e L9 = measurements with tool 380001630 fitted on the reference surface (L5, fig. 42) or on the transmission housing (L9).
39. Check that the distance (L7) is at least 0.1968 in. (5 mm) greater than the distance (L6).
40. Slacken the locknut (4) and adjust the length of the draft control rod until it protrudes by a new distance (L7 = 0.9212 to 0.9291 in. (23.4 to 23.6 mm)).
41. This distance (L7) can be calculated by subtraction using tool 380001630
L10 = L5 − L7 where: L7 = 0.9212 to 0.9291 in. (23.4 to 23.6 mm). Distance the end of the rod (3) protrudes with respect to the transmission casing. L5 = distance measured with tool 380001630 fitted on the reference surface. L10 = distance to be measured with the micrometer gauge on the tool 380001630.
42. Tighten the locknut (4) and fit the lift on the tractor.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
28
OP. 35 110 08 ROD MECHANISM ADJUSTMENTS Position control rod adjustments Proceed as follows. 1. Move the position control lever (1) forward completely on the quadrant and check that the distance (L) is 0.1968 to 0.3937 in. (5 to 10 mm).
45 2. Move the external position control lever (1) completely back against the spacer.
1
2
3. Connect the control linkage and adjust its length if necessary. 4. Secure the rod in position using the locknuts.
25496
46 Draft control rod adjustments Test Conditions: −
engine running at medium speed;
−
allow the oil in the system to reach a temperature of 86 to 104 °F (30 to 40 °C). Then proceed as follows: 5. Move the position control lever (1) forward completely on the quadrant and the draft control lever (2) to a distance (L1) of 0.1968 to 0.3937 in. (5 to 10 mm) from the beginning of the slot. 47
6. Move the external draft control lever (2) completely back against the spacer.
1
2
7. Connect the control linkage and adjust its length if necessary.
25496
48 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
29
8. Move the draft control lever (2) to a distance (L2) of 4.0551 to 4.2519 in. (103 to 108 mm) from the beginning of the slot and check that in this position the arms start to rise. 9. If the arms do not rise, adjust the eccentric pin (1, fig. 38) to reset this distance. 10. Lock the pin in position using the locknut.
49 Adjusting LIFT−O−MATIC device Proceed as follows. 11. Move the position control lever (1) and the draft control lever (2) completely forward on the quadrant.
50 12. Raise the arms by means of the lever (1).
1
2
25499
51 13. Tighten the nut (1) until the arms lower. 14. With the lever (1, fig. 51) still in the same position, unscrew the nut (1) until the arms begin to rise.
1
15. Unscrew the nut (1) by another 1.5 turns. 16. Using the levers (1 and 2, fig. 51) lower and raise the arms a few times to ensure that the device is operating correctly.
25500
52 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
30
LIFT ARM DESCENT SPEED ADJUSTMENTS
1
2
Test Conditions: − −
apply a load of 220.56 lbs. (100 kg) to the link ends of the lower implement attachment arms; allow the oil in the system to reach a temperature of 122 to 140 °F (50 to 60 °C).
Proceed as follows. 1. Fully raise the arms. 2. Slacken the lock nut (1).
25501
53 3. Lower the arms and, by means of the screw (2), adjust the lowering speed to a time of 2 to 2.5 seconds (by tightening the screw the time decreases, by unscrewing the screw the time increases). 4. Tighten the locknut (1), making sure that the screw remains stationary (2).
UPPER STROKE LIMIT ADJUSTMENT CHECK Test condition. − −
apply a load of 220.56 lbs. (100 kg) to the link ends of the lower implement attachment arms;
54
allow the oil in the system to reach a temperature of 122 to 140 °F (50 to 60 °C).
1
Proceed as follows. 1. Move the position and draft control levers (1 and 2, fig. 54) completely forwards on the quadrant.
2
2. Raise the arms (1) until the internal arm comes into contact with the lift body, stamp two corresponding reference marks (2) on the lift body and the arm. 25503
55 3. Start the engine and, using the position control lever (1, fig. 54), raise the arms (1) and check that there is a distance (A) of 0.0787 to 0.1574 in. (2 to 4 mm) between the reference marks (2).
1 2
A 25504
56 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
31
OPERATIONS TO BE PERFORMED TO ADJUST THE UPPER STROKE LIMIT OF THE LIFT−O−MATIC DEVICE
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
1
Proceed as follows: 1. Apply a load to the link ends of the lower implement attachment arms. 2. Start the engine and keep it running at medium speed. 3. Hold down the pushbutton (1) until the arms are in the attachment position (completely lowered). 25505
57 4. Move the levers (1 and 2) completely forward on the quadrant (completely lowered). 5. Using the position control lever (1) raise the arms to the desired height. 6. Stop the engine. 7. Press the LIFT−O−MATIC pushbutton (arms raise).
58 8. Slacken the lever (1) and turn the mobile sector (2) clockwise until it touches the needle (3) on the LIFT−O−MATIC control lever (4). 9. Use the LIFT−O−MATIC control buttons to raise and lower the arms a few times to ensure correct operation.
1 2
3
NOTE: The arm upward stroke limit only applies to the LIFT − O − MATIC device and does not affect the other functions of the lift. This means that the arms can be raised completely using the control levers (1 and 2, fig. 58).
4 25506
59
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
32
OP. 35 110 42 ARM SHAFT AND LIFT CYLINDER DISASSEMBLY−ASSEMBLY (With the lift removed) Disassembly
DANGER Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows.
1
1. Remove the front bolts, the rear union and recover the oil delivery pipe (1) to the lift cylinder. 2. Remove the three lift cylinder retaining bolts.
25456
60 3. Remove the lift control cylinder (1).
1
25460
61 4. Loosen the nut (4) and recover the locking lever (3) on the lifting stroke limit cam (1), unscrew the nut (2) and remove the cam (1).
1 2 3 4 25464
62
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
33
5. Unscrew the retaining bolt (3) and recover the thrust washer (2) and the lifting arm (1).
Carry out this operation on both sides.
1 3
25465
2 63
6. Straighten the securing ring and unscrew the retaining bolt that secures the ring−cam to the internal arm (1).
1
25466
64 7. Using a brass drift, strike the end of the shaft (2), extract the shaft and recover the internal arm (1), the ring−cam and the seal (3).
1
3
2 25467
65 8. Use compressed air to remove the piston (2) from its cylinder (1).
1
2
26297
66 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
34 Assembly
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. To refit the arm shaft and lifting cylinder, proceed as follows. − Study the illustrations in figs. 4, 5 and 6 for the positioning of the various parts. − Apply the torque settings listed on page 3. 9. Using tool 380001627 (2) insert the piston (1) in the relative cylinder (3).
1
2
3
25634
67 10. Fit the lift arm shaft (2), the ring−cam and the internal arm (1) inside the lift box, matching up the reference marks. Tighten the bolt that secures the ring−cam to the internal arm and stake the retaining bolt washer.
1
2 25468
68 11. To avoid damaging the internal seal lips (2), use a flexible brass sheet (1) dimensions: 7.874 x 3.5433 in. (200 x 90 mm) and 0.0019 to 0.0039 in. (0.05 to 0.1 mm). Roll up the sheet and insert the seal inside. Position the unit on the spline and push the seal manually into its seat, then remove the sheet.
1
2 26300
69
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 12. Using the drift 380001628 (1), complete the fitting of the seals into the relative seats on the arm shaft.
35
1
26326
70 13. Fit the lift arms (1) on the shaft, matching up the reference marks. Secure in position with the bolts and washers.
1
25469
71 14. Fit the lifting stroke limit cam (1), nut (2) and the relative locking lever (3) and the lock nut (4).
1 2 3 4 25464
72 15. Fit the control cylinder, securing in position with the three retaining bolts.
1
16. Fit the oil delivery pipe (1) to the control cylinder.
25456
73 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
36
OP. 35 114 14 LIFT CONTROL VALVE D.A. (with control valve removed) Disassembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows. 1. Before disassembly, thoroughly clean the surfaces of the control valve block. Lock the control valve block in a vice, loosen the screws and remove the union (1). 2. Unscrew the locknut (2) and recover the spacer (3).
1
2
3
25484
74 3. Remove the cap (1), complete with speed intervention adjustment valve, seat (3), piston (2) and control valve shutter (4).
1
2
3
4
25485
75 4. Unscrew the cap (2) and remove the control valve spring (1).
1
2
25486
76
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1 5. Remove the cylinder safety valve (4) and recover the arm lowering speed adjustment valve (3), the spring (2) and the pin (1).
1
2
37
3
4
25709
77 6. Unscrew the cap (1) and remove the spring (2), the control valve block pin (3) and seat (4).
1
2
3
4
25487
78 7. Remove the check valve, comprising: ball (1), spring (2) and union (3).
1 2 3
25488
79 8. Check the wear of the seals on the control valve block−pin seat. If damaged, replace the seals using protection device 380000275 (1) and following the instructions on page 11.
1
To check the efficiency of the control valve block pin, proceed as follows.
25714
80 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
38
9. Fit the control valve block pin (2) complete with seat (3) on the tool 380000274 (1).
1
2
3
25715
81 10. Fit the control valve block pin spring (1) and the cap (2) of tool 380000274. Tighten the cap as far as it will go and check that the control valve block−pin slides in its seat.
1
2
25716
82 11. Fit tool 380000274 (2) on the hand pump 380000215 (3), supplied with HYDROSYSTEM 68 oil. Connect a dial gauge (1), securing in position with the screw.
1 2 3
25717
83 12. Operate the hand pump, whilst tightening the tool screw (1), until the oil stops flowing out through the control valve block pin seat outlet.
Zero−set the dial gauge.
1 Tighten the screw (1) on the tool further to move the control valve block pin by 0.0708 to 0.0787 in. (1.8 to 2 mm), using the dial gauge to read this distance.
25718
84 87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
39
13. Operate the hand pump until the oil in the system is at an initial pressure of 3552 psi (245 bar) and, using the pressure gauge, check that it takes more than six seconds for the pressure to fall from 2842 psi (196 bar) to a value of 1421 psi (98 bar). If it takes less than this time, replace the control valve block pin. Bear in mind that this part is supplied together with the relevant seat.
25719
85 14. Fit the cylinder safety valve (1) on the valve union 380000218 (2) and connect to the hand pump 380000215 (3).
1
2
3
15. Operate the hand pump (3) and check that the cylinder safety valve opens at a pressure of 3045 to 3117 psi (210 to 215 bar). If the valve setting does not correspond to the prescribed value, it is best to change it immediately. If necessary it can be adjusted by turning the threaded cap, using wrench 380000230. Tighten to increase the valve setting value or loosen to reduce the value.
Assembly
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
16. To refit the hydraulic control valve block, proceed as follows: −
Refer to the instructions on page 11 for the positioning of the various parts.
−
Respect the tightening torques prescribed on page 3.
−
Fit the control valve block pin.
−
Fit the non−return valve.
−
Fit the cylinder safety valve.
−
Fit the control valve.
−
Fit the intervention speed adjustment valve.
−
Fit the oil infeed union.
25720
86
87744428A − 11 − 2007
40
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 1
OP. 35 114 30 LIFT PRESSURE RELIEF VALVE REMOVAL−INSTALLATION Proceed as follows. 1. Remove the protective guard. 2. Remove the relief valve (1) and, if faulty, replace. 3. Re−position the protective guard.
1
OP. 35 114 32 LIFT PRESSURE RELIEF VALVE (CALIBRATION) 25507
87 Proceed as follows. 1. Run the engine until the oil in the system reaches a temperature of approximately 122 °F (50 °C).
1
2. Insert the union 380000554 (1) in a quick−fit female half−coupling and connect it to the 0 to 250 kg/cm@ scale pressure gauge, supplied with kit 380000240. 3. Activate the half−coupling control valve block lever until the pressure relief valve cuts in. 4. With the engine running at medium speed the pressure gauge must show a pressure of about 2697 to 2769 psi (186 to 191 bar). If the valve setting does not correspond to the prescribed value, it is best to change it immediately. If necessary it can be adjusted by turning the threaded cap, using wrench 380000231. Tighten to increase the valve setting value or loosen to reduce the value.
87744428A − 11 − 2007
25508
88
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 2
1
SECTION 35 − HYDRAULIC SYSTEMS Chapter 2 − Open centre system auxiliary control valves CONTENTS Operation
Description
Page
Main data − Tools − Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift − Chapter 1 35 130 30
Lift electronic control centre (Replacement). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
35 204 46
Auxiliary control valves. Disassembly − Assembly (with the unit removed) . . . . . . . . . . . . 9
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SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 2 DATA
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auxiliary control valves Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full−flow, with replaceable paper cartridge, (common to the hydraulic lift circuit) gear pump (common to the hydraulic lift circuit, see Chapter 4) valve stack up to a maximum of 4 valves attached to the lift housing
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
by hand lever
Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . psi (bar)
2755 to 2827 (190 to 195)
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.
TOOLS Warning − The operations described in this section must only be performed with the ESSENTIAL tools marked with 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.
380000240
Universal pressure testing kit.
380000241
Seal guard for Kontak control valve check valve.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ TIGHTENING TORQUES
Parts to tighten
Thread
Tightening Torque
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
3
A
1
2
3
4
B
5
6
7
8
9
10
11
27 28 29 30 31 26
C
25 24
23
22
21
20
19
18
17
25723
A. B. C.
D.
E.
Auxiliary control valve cross−sectional views (fig. 1− 2− 3) Auxiliary control valve configured for operation 12. Seal. of a double−acting cylinder. 13. Cup. Auxiliary control valve configured for operation 14. Control valve stem return spring. of a single−acting cylinder. 15. Cover. Auxiliary control valve configured for operation 16. Spacer. of a single/double−acting cylinder with float 17. Tapered needle. control and automatic detent release. 18. Spring. Auxiliary control valve configured for operation 19. Seal. of a single/double−acting cylinder with auto20. Detent balls. matic detent release. 21. Seal. Auxiliary control valve configured for operation 22. Seal. of a single/double−acting cylinder with switch23. Internal plunger. ing float control. 24. Spring. Single/double−acting operation switching valve. 25. Cover. Seal. 26. Detent release pressure adjuster screw. Valve retaining plug. 27. Control valve stem return spring. Seal. 28. Cup. Seal. 29. Seal. Check valve seat. 30. Detent notch body. Non−return valve. 31. Detent ball support. Seal. 32. Gasket. Seal. 33. Gasket. Control support.
1
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Control valve stem.
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SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 2
1
2
3
4
5
6
7
8
9
10
11
28 29 30 31 27 26
D 25 24
23 22
21
20
19
18
17
25724
2
1
30
32
2
3
4
5
6
7
8
9
10
11
33
28
E 25 24
20
18
17
25725
3
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5
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 hand levers located on the right−hand side of the driving position. 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 follows:
ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Lever colour Green Blue Brown
4. Float (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 terrain.
Control valve position/No. RH external RH internal RH rear
−I −II −III
The operation of the hydraulic 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 A 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 bottom chamber of the cylinder with the delivery line (E) by way of the check valve (3) and line (G) and also to connect the top chamber of the cylinder with the exhaust line (L) by way of line (H), intercepting the supply of oil to the lift control valve. Keep the lever pulled 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).
1
L
H
3
E
G
L
2
22123
M 4
L
H
3
E
G
L
2 2. LOWERING − To lower the implement, push the control lever (located in the cab). The control valve spool (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 spool (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 spool (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).
22124
5
1
L
H
3
E
G
L
2
22125
6
L
H
3
E
G
L
Pressurized oil Oil in suction, delivery or exhaust
2
Static oil NOTE: For operation of a double−acting cylinder, tighten the screw (1). For operation of a single−acting cylinder, loosen the screw. 22126
7
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7
OPERATING STAGES OF AUXILIARY CONTROL VALVE FOR THE OPERATION OF A SINGLE/ DOUBLE−ACTING CYLINDER WITH AUTOMATIC DETENT RELEASE AND FLOAT POSITION Pressurized oil Oil in suction, delivery or return
H
L
E
3
G
L
Oil at static rest
6
24
28
26
T
23 2
Y
M
22127
8
LIFTING On pulling back the control lever (located in the cab), the spool (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 2465 to 2537 psi (170 to
L
H
175 bar), 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 detent ball 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).
E
3
G
L
2
22128
9
LOWERING To lower the implement, push forward the control lever (in the cab). The control valve spool (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 POSITION
Oil in suction, delivery or return
L
Oil at static rest
28
22129
H
G
L
26
2
24
M 10
FLOAT OPERATION For float operation push forward the control lever (in the cab). The spool (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. With float operation the automatic detent release function is excluded, as there will be insufficient pressure in 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.
1
2
3
4
NOTE: For operation of a double−acting cylinder, tighten the screw (1). For operation of a single−acting cylinder, loosen the screw. 25726
11
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OP. 35 204 46 AUXILIARY CONTROL VALVES Disassembly − Assembly (with the unit removed)
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE YOUR 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 spool (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.
3 1
4
5
2
8
7
6
24452
12
Single/double−acting auxiliary control valve with float control and automatic detent release
1
2
3
4
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 screws, recover the cover (4) and the spacer (3). 2. Unscrew the retaining screws, recover the control lever support (1) and relative seal (2). 24453
13
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SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 2
3. Extract the spool (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 spring. 6. Check the condition of the seals before assembly. Diagram showing the installation of the tools and equipment required for the spool sticking test for control valves configured for double− acting operation (fig. 15) and control valves configured for single−acting operation (fig. 16).
1
24454
14 Control valve spool 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. 140 °F (60 °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 referring to the following instructions:
15
−
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 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 spool (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 2494 psi (172 bar). 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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11
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 3−way union (1) must be connected to single and double acting control valves using suitable adapters. 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 2131 psi (147 bar) 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 1.5255 in3/minute (25 cm3/minute) in the case of a new control valve, or 3.6612 in3/minute (60 cm3/minute) for a used valve.
Repeat the test on each control valve, checking alternately the two delivery lines to the 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 2465 to 2537 psi (170 to 175 bar) is obtained in front of the tapered cap (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
1
SECTION 35 − HYDRAULIC SYSTEMS Chapter 3 − Trailer brakes auxiliary control valves CONTENTS
Operation
Description
Page
Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 33 220 40
Trailer brake valve. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
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 operation is described 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. Slide piston.
1
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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.
1
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.
2
3 4
P1
5
6
N
The majority of the oil flows through the port (N) to the auxiliary control valves, while the rest of the oil is discharged to the hydraulic lift through the line (4), the spool (7) and the port (R).
B 7
R
25259
Y
Pressurized oil Oil in suction, delivery or return 2 Oil at static rest Tractor brake circuit oil (brakes off) Pressurised tractor brake circuit oil
Trailer brakes off. N. To the auxiliary control valves. P1. From the hydraulic pump to the lift circuit. R. To the lift return line. Y. From the tractor brakes.
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 spool (8) which closes the passage between the oil return port (R), trailer brake port (B) and the line (5).
1
The oil inside the flow control valve (4) is maintained at a uniform pressure, allowing the valve element, under the action of the spring, shifts to the left to assume the position indicated in fig. 3.
P1
Part of the oil from the hydraulic pump in port (P1) flows to the auxiliary control valves through port (N), while the remaining part arrives at the tractor braking element via the diaphragm (2), line (3), check valve (1) and port (B).
B
2
3
4 5
6
7
N
25261
9
R
8
Y 3
As the pressure of the oil in the trailer brake port (B) increases, it acts on the active surface (9) of the stem (8), opposing the pressure applied on piston (7) by the oil in the hydrostatic tractor brake circuit.
Start of braking. B. To the trailer brake. N. To the auxiliary control valves. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.
87744428A − 11 − 2007
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) increase 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 slide piston (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).
1
2
3
4
3
5 6
P1
7
8
B 10
R
Y
9
25260
4 The diaphragm (2) and the restriction (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).
Further pressure on the tractor brake pedals shifts the piston (7, fig. 3), the pressure limiter (8) and the slide piston (2), thus causing an increase in the trailer brake circuit pressure, repeating the stages described in the paragraph START OF BRAKING.
Braking. B. To the trailer brake. P1. From the hydraulic pump to the lift circuit. R. To the return line in the lift. Y.
From the tractor brakes.
Pressurized oil Oil in suction, delivery or return Oil at static rest Pressurised tractor brake circuit oil
If the pressure in the trailer brake circuit increases as a result of external causes, the slide piston (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.
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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4
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
2
1
4 21
5a
20 3 18
19 5b
16 22 15
6
17
14 12 Oil in suction or delivery Discharge oil Tractor brake circuit oil (brakes off) Oil at trailer brake release pressure
13
7
11
8 9
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10
5 ELECTRO−HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running − no action on brake pedals 1. Parking brake lever − 2. Relay − parking brake warning light circuit − 3. Relay − trailer brake circuit − 4. Trailer brake 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. Service brake 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 159.5 to 174 psi (11 to 12 bar). Oil at a pressure of 159.5 to 174 psi (11 to 12 bar), 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.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
5
2
1
4 21
5a
20 3 18
19 5b
16 22 15
6
17
14 12
13
A
7
11
8
Oil in suction or delivery
9
25262
Discharge oil
10
Pressurised tractor brake circuit oil Oil at tractor brake release pressure 6
ELECTRO−HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running − brake pedals pressed A. Line connecting brake pump (13) to trailer brake valve (7) − 1. Parking brake lever − 2. Relay − parking brake warning light circuit − 3. Relay − trailer brake circuit − 4. Trailer brake 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. Service brake 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 port (R) and consequently the pressure in the delivery line from the hydraulic pump (9) increases. The pressurised oil 174 to 2175 psi (12 to 150 bar) 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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6
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
2
1
4 21
5a
20 3 18
19 16
5b 22
15
6
17
14 12
13
7
11
8 9
25263
Oil in suction or delivery
10
Discharge oil Brake circuit oil at rest 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 lever − 2. Relay − parking brake warning light circuit − 3. Relay − trailer brake circuit − 4. Trailer brake 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. Service brake 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 piston (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
7
2
1
4 21
5a
20 3 18
19 16
5b 22
15
6
17
14 12
13
7
11
8 9
25264
Oil in suction or delivery
10
Discharge oil Tractor brake circuit oil (brakes off) 8
ELECTRO−HYDRAULIC OPERATION OF TRAILER BRAKE VALVE (ITALIA VERSION) Engine running − with parking brake on 1. Parking brake lever − 2. Relay − parking brake warning light circuit − 3. Relay − trailer brake circuit − 4. Trailer brake 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. Service brake 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 applying the parking brake (1), switch (21) is closed. This allows electrical current to energise 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 piston (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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8
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3 FUNCTIONAL TESTING AND TROUBLESHOOTING OF TRAILER BRAKE VALVE − ITALIA VERSION
Oil temperature 104° to 122 °F (40° to 50 °C). 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 to 40 kg/cm2 from kit 380000240. 2. With the engine running at the prescribed speed and the oil at the prescribed temperature, the pressure should be 159.5 to 174 psi (11 to 12 bar). 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
9
FAULT DIAGNOSIS Problems Possible Causes Trailer brake release pressure = 1. Parking brake (1, fig. 8) enga0 bar (warning light 22, fig. 8 ON). ged. 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. Replace the valve.
Replace the switch.
Overhaul or replace 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 pressure release 0 to 159.5 psi (0 to 11 bar).
1. Trailer brake release pressure Replace the valve. control valve (6) incorrectly adjusted.
Trailer brake release pressure correct, but warning light (22) illuminated.
1. Trailer brake warning light Replace the switch. switch (16) faulty.
Trailer brake release pressure incorrect, but warning light (22) not illuminated.
1. Warning light (22) bulb faulty.
Change the lamp bulb.
2. Trailer brake warning light Replace the switch. switch (16) faulty. NOTE: Switch (8) can be identified by the red paint mark between the two terminals.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
9
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 to 250 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, apply a force of 30 to 35 daN (29.4 to 34.3 kg/cm2) to the service brake pedals; the pressure reading on the gauge should be 1957 to 2102 psi (135 to 145 bar). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
25751
10
FAULT DIAGNOSIS Problems Pressure above or below prescribed range.
Possible Causes
Solutions
1. Pressure control valve (6, Replace trailer brake auxiliary fig. 8) of trailer brake auxiliary control valve. control valve faulty. 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 to 250 kg/cm2 from kit 380000240. 2. With the engine and the oil in the test conditions described at the beginning of the chapter, apply a force of 30 to 35 daN (29.4 to 34.3 kg/cm2) to the service brake pedals; the pressure reading on the gauge should be 1957 to 2102 psi (135 to 145 bar). 3. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
25751
11
FAULT DIAGNOSIS Problems
Possible Causes
Solutions
On applying the prescribed force 1. Oil leaks in the hydraulic sy- Find and eliminate the leaks. on the service brake pedals, stem. there are an excessive number of pressure peaks over a 10−second period. 2. Excessive leakage from the so- Replace solenoid valve. lenoid valve (5b, fig. 8). 3. Excessive leakage from trailer Replace trailer brake auxiliary brake control valve (7). control valve.
87744428A − 11 − 2007
10
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 to 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). 3. Check that the pressure is 0 bar and that warning light (22, fig. 8) is ON. 4. With the parking brake applied, disconnect the pressure gauge and union 380000550 (1). 25751
12
FAULT DIAGNOSIS 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 the switch. faulty. 2. Parking brake indicator relay Replace 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 to 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: 159 to 174 psi (11 to 12 bar). 25751 4. Apply the parking brake and disconnect the pressure gauge and union 380000550 (1).
13
FAULT DIAGNOSIS Problems
Possible Causes
On carrying out the operation described above, the trailer brake release pressure is nullified permanently.
1. Trailer brake circuit safety switch (8, fig. 8) setting higher than the nominal pressure 43.5 ± 7.25 psi (3 ± 0.5 bar). 2. Switches (8 and 16) installed in incorrect positions, or electrical leads connected incorrectly.
Solutions Replace the switch.
Install the two switches in their correct positions or swap over the electrical power leads.
NOTE: Switch (8) can be identified by the red paint mark between the two terminals.
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
11
OP. 33 220 40 TRAILER BRAKE VALVE Removal − Installation Removal
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
1. Position a container (3) to collect the oil discharged from the system pipes.
2. Disconnect the pipes (1) connected to the trailer brake valve.
3. Remove the two trailer brake valve retaining bolts (2).
27890
14
4. Disconnect the trailer brake valve (1).
Installation
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
27891
15 Proceed as follows.
5. Fit the trailer brake valve (1,fig. 15) and lock it with the two retaining bolts (3, fig. 14), refit the pipes (2) connected to the valve and remove the container (1).
87744428A − 11 − 2007
12
87744428A − 11 − 2007
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 3
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 4
1
SECTION 35 − HYDRAULIC SYSTEMS Chapter 4 − Non−stop flow gear pump CONTENTS Operation
Description
Page
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings − Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift − Chapter 1 35 104 30
Lift circuit hydraulic pump. Disassembly − Assembly (with unit removed) . . . . . . . . . . . . . . . 4
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ MAIN SPECIFICATIONS OF HYDRAULIC PUMP C 42
Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . in3/min (I/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . Clearance between gear shafts and seats . . . . . . . . . . . . . . . − maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . .
in. (mm) in. (mm) in. (mm) in. (mm)
gear type with oil suction from rear transmission casing on RH side of engine C 42 NEW HOLLAND driven by engine shaft clockwise 1 : 1.08 2484 2890.1653 (47.36) 1163.1451 (19.06)
0.6850 to 0.6857 (17.400 to 17.418) 0.6870 to 0.6879 (17.450 to 17.475) 0.0012 to 0.0029 (0.032 to 0.075) 0.0039 (0.1)
Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . in. (mm) maximum wear on pump body, suction side at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm)
0.0007 to 0.0025 (0.020 to 0.064)
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm) Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm) Width of pump body for gear seats and supports . . . . . . . . . . Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . . . . in. (mm)
1.2125 to 1.2131 (30.800 to 30.815) 0.9641 to 0.9649 (24.490 to 24.510) 3.1470 to 3.148 (79.935 to 79.960)
0.0039 (0.1)
0.0039 to 0.0070 (0.100 to 0.180)
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SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 4
2
MAIN SPECIFICATIONS OF BOSCH 25 HYDRAULIC PUMP
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . gear type with oil suction from rear transmission casing. on RH side of engine Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH 25 Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BOSCH Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . driven by engine timing Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . clockwise 1 : 1.08 Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . . . . . . . . . . . Engine speed to pump speed ratio Maximum speed of rotation 2484 (with engine at maximum power 2300 rpm) . . . . . . . . . . . . . . . . . . . . . . . . rpm 3895.8647 (63.84) Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . in.3/min (I/min) 1568.3541 (25.7) Rated out at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in.3/min (I/min)
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full−flow, with replaceable paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
on pump intake
Tightening torque PARTS TO BE TIGHTENED
Thread
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 20 UNF
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Nm
kgm
29
3
DESCRIPTION AND OPERATION The front hydraulic pump serves the hydraulic lift, the trailer brake valve and the auxiliary control valves. 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.
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They are fitted on the right hand engine support and are driven by a shaft gear unit. The oil is taken from the rear transmission casing, passing through a filter.
SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 4
3
25719
1 Components of C 42 pumps, BOSCH 25 1. 2. 3. 4. 5. 6. 7.
Nut. Lock washer. Circlip. Driving shaft seal. Control side cover. Cover seals. Gear support.
8. 9. 10. 11. 12. 13.
Driven and driving gear shafts. Gear support. Pump body. Front cover. Lock washer. Bolt.
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SECTION 35 − HYDRAULIC SYSTEMS − CHAPTER 4
4
PUMP MODELS C 42, BOSCH 25 OP. 35 104 30 LIFT OIL PUMP Disassembly − Assembly (with pump removed) Disassembly
CAUTION
2
Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows:
25227
2 1. Remove the bolts and the relative safety washers (12) on the cover (13, fig. 1). 2. Remove the nut (1) that secures the sleeve to the pump driving shaft and the safety washer (2). 3. Remove the front cover (5), the circlip (3) and the seal (4). 4. Mark the parts (7, 8, 9 and 10), in order to re−fit them in the same position, if in good condition. 5. Remove the supports (7 and 9) and gears (8) from the front cover (5) and the pump body (10). 6. Recover the seals (6) and the anti−extrusion rings. Once the parts are removed, proceed as follows: 7. Check that the gear contact surfaces are flat and perpendicular to their supports. Interpose a thin layer of carbon black; small rough spots can be removed using extremely fine and adequately lubricated abrasive paper. 8. Check that the axial play of the gear−support unit in the pump body is 0.0039 to 0.0070 in. (0.100 to 0.180 mm). The distance (2, fig. 2) must be 0.0039 to 0.0070 in. (0.100 to 0.180 mm) less than the distance (1). If necessary, true the flat surfaces involved using lubricated abrasive paper to remove extremely small quantities of material. 9. Clean all constituent parts thoroughly. 10. Replace the seals (4 and 6). 11. Lubricate the parts with the same oil as the system.
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Assembly
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
12. To re−fit the pump carry out operations 6 to 1 in reverse order, referring to fig. 1 proceeding as follows: −
always ensure maximum cleanliness to prevent foreign matter from entering and damaging the pump;
−
fit together the previously marked parts (10, 7, 8 and 9), referring to operation 4, in the original positions;
−
mount the gear supports (7 and 9) in the pump body, positioning as shown in fig. 1;
−
insert the plastic anti−extrusion rings on the seals (6);
−
mount the seals (4), on the control side cover (5) facing towards the inside;
−
Fit the covers (5) and (11), position the washers (12) and tighten the retaining bolts (13);
−
Fit the washer (2) and the locknut (1).
SECTION 41 − STEERING − CHAPTER 1
1
SECTION 41 − STEERING Chapter 1 − Steering CONTENTS Operation
Description
Page
Torque settings main data − tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 41 204 10
Hydrostatic steering wheel − Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
41 204 30
Hydrostatic steering control valve − Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . 10
41 204 34
Hydrostatic steering control valve (removed) − Disassembly − Assembly . . . . . . . . . . . 13
41 204 38
Hydrostatic steering control valve − Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
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2
SECTION 41 − STEERING − CHAPTER 1 DATA
HYDROSTATIC 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ORBITROL, with the rotating valve controlled directly by the steering column; the steering continues to function even if the pump is damaged
Outfit 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) . . . . . . . . . . . . . . . . . . .
psi (bar)
2392 to 2465 (165 to 170)
Cylinder safety valve calibration (33, fig. 2) . . . . . . . . . . . . . . . . . . .
psi (bar)
3335 to 3480 (230 to 240)
TIGHTENING TORQUES Tightening torque PARTS TO BE TIGHTENED
Thread Nm
kgm
Bolt securing cover to power steering housing (21, fig. 4) . . . .
M8x1
24 to 36
2.5 to 3.7
Steering column flange retaining nut . . . . . . . . . . . . . . . . . . . . . .
M8x1
23
2.40
Bolt securing power steering to tractor . . . . . . . . . . . . . . . . . . . .
M 10 x 1.5
44
4.5
Hydrostatic steering control pump retaining bolt . . . . . . . . . . . .
M6x1
8
0.8
Nut for pump housing cover retaining bolt . . . . . . . . . . . . . . . . . .
M 10 x 1.25
39
4
Nut for securing thrust sleeve to pump drive shaft . . . . . . . . . . .
7/16”−20UNF−2B
28
2.8
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.
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List of specific tools required for the various operations described in this Section. X 380000223 Steering wheel extractor. X 380000307 Power steering rotor retaining lever. X 380000240 Universal pressure testing kit. 380000306 Plug for fitting the power steering rotating valve return springs. X 380000281 Tool for fitting power steering Rotoglyd seal. X 380000836 Tool for fitting power steering Varisel seal.
SECTION 41 − STEERING − CHAPTER 1
3
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 ducts (13 and 14) are aligned (sect. C−C) and the oil, from the pump (P), flows freely to and from the reservoir; − 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: − the ducts are not aligned (13 and 14, sect. C−C), therefore the oil discharge flow is interrupted; − the six grooves are aligned (15, sect. D−D) with the same number of ducts (16), that are connected with the compartments on the rotor in the suction phase; − the six delivery grooves are aligned (17, sect. E−E) with the ducts (18) connected to the cylinder and, at the same time, the grooves are aligned with the remaining ducts (16, sect. D−D), that are connected with the compartments on the rotor in the delivery phase; − the alignment of the six discharge grooves (19) with the ducts (20, sect. E−E) connecting to 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 pin (9, page 4) and the shaft (11). 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 Power steering operation sectional views 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 (11) − 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).
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4
SECTION 41 − STEERING − CHAPTER 1
M
S 14
13
V
16
5 13714
A
P
G Z
R D H
F
27
24 21
23 15
R− ht
17
19
4
9
26
5
6
16
21
33
V
33
34 B
L− ht
13723
Delivery oil to control cylinder Delivery oil to rotor Intake oil, low pressure delivery or discharge Static rest oil
D M
El− ht
S
23 Er−ht 4
13722
C 87744428A − 11 − 2007
2
SECTION 41 − STEERING − CHAPTER 1
17
15 D−D
F−F
21 16
17
9
d
15
e 17
15
7884
5
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. 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 rotor reservoir. 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.
f 3
Power steering operation circuit sectional views (*see fig. 1) A. B.
Neutral position operation diagram. 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. 4. Non−return valve.
5. Rotating valve. 6. Valve seat sleeve (5). 9. Rotor. 13 and 14. Oil flow ducts in the neutral position. 15. Delivery grooves (no. 6) to the compartments on the rotor in the suction phase. 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.
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6
1. 2. 3. 4. 5. 6. 7. 8. 9.
SECTION 41 − STEERING − CHAPTER 1
Hydrostatic steering control valve components 10. O−ring. Dust ring. 11. Shim ring. Control valve body, rotary valve and rotary valve 12. Cover retaining screws. seat sleeve. 13. Washers. Non−return valve ball. 14. Cover. Seal. 15. O−rings. Non−return valve threaded plug. 16. Rotor and fixed ring for rotor. Thrust bearing components. 17. Springs for returning sleeve to neutral position. Retaining ring for springs (17) (Danfoss only). 18. Pressure relief valve. Rotor drive shaft − sleeve trim pin. 19. Cylinder safety valves. Rotor drive shaft.
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SECTION 41 − STEERING − CHAPTER 1
7
POWER STEERING TROUBLESHOOTING Problems Oil leaking from the power steering unit: a. Control side. b. Cover side.
Possible Causes
Solutions
1. VARISEAL seal (4, page 6) Replace the ROTOGLYD seal using the specific tool 380000281 or defective. 380000836 for VARISEL seals. 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.
1.
With the engine stopped, the steering wheel can be turned without turning the wheels.
1.
2. 3.
Tighten the bolts to the prescribed torque (24 to 36 Nm − 2.5 to 3.7 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 (24) jam- Eliminate foreign bodies and clean med or held open by foreign filter. bodies. 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 fati- Renew the springs. gued. Inadequate control cylinder Replace the seal. seal. Cylinder rod broken. Replace the damaged part. Rotor drive shaft or pin bro- Replace 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 da- filter or replace the control valve. maged. (continued)
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8
SECTION 41 − STEERING − CHAPTER 1 POWER STEERING TROUBLESHOOTING (cont)
Problems
Possible Causes
Solutions
Steering wheel jolts, steering 1. Incorrect synchronisation of Synchronise correctly. uncontrollable, wheels steering in power steering. Connect correctly. 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. Control valve mechanical wear.
Replace the seal. Eliminate foreign bodies and clean filter or replace the control valve. Replace the control valve.
Neutral phase of power steering 1. Leaf springs, for sleeve return Replace the leaf springs assembly. unobtainable. to neutral position, damaged or fatigued. During manual control, operation is normal; when stopping manual 2. Sleeve and rotating valve loc- Eliminate foreign bodies and clean control the steering wheel tends ked in delivery position becau- filter. to move on its own, or remain se of the presence of foreign stationary, but steering continues bodies. slowly in the direction that was 3. Sleeve crushed on the rotating Check the pressure relief valve initially selected (“motoring”), valve due to excessive pres- calibration. therefore steering must be sure. continually corrected with the steering wheel. Vibrations on front wheels (shimmy).
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.
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Bleed the air and eliminate the causes of possible infiltration. Replace the worn parts. Eliminate foreign bodies and clean filter or replace the control valve. Check the hydraulic pump and the pressure relief valve calibration. Replace the control valve. Eliminate foreign bodies and clean filter or replace the control valve.
SECTION 41 − STEERING − CHAPTER 1
9
Op. 41 204 10 HYDROSTATIC STEERING WHEEL Replacement
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Using a suitable tool, remove the NEW HOLLAND symbol at the centre of the steering wheel, unscrew the nut and the central knob (1).
4
2. Remove the steering wheel retaining nut and, using tool 380000223 (1), remove the steering wheel.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
3. To re−fit the steering wheel on the column, proceed as follows. 4. Position the steering wheel on the column and secure with the nut.
5
5. Fit the knob with the NEW HOLLAND symbol at the centre of the steering wheel.
87744428A − 11 − 2007
10
SECTION 41 − STEERING − CHAPTER 1
Op. 41 204 30 HYDROSTATIC STEERING CONTROL VALVE Removal − Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
To remove the hydrostatic steering control valve, proceed as follows: 1. Carry out operation 90 100 22 Bonnet, only removal (see Section 90). 2. Carry out operation 90 100 84 Bonnet guard, only removal (see Section 90). 3. Carry out operation 41 204 10 Hydrostatic steering wheel, only removal (see page 9). 4. Carry out operation 55 418 10 Multi−indicator panel, only removal (see Section 55, Chapter 6). 5. Remove the instrument panel upper guard retaining bolts (1).
6
6. Remove the steering column dust guard (1).
7 7. Loosen the screw and detach the hand throttle control lever grip (1).
8 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
11
8. Remove the fuse box cover (1), unscrew the retaining screws and remove the fuse box.
9 9. Unscrew the indicator lights switch ring nut (1).
10 10. Unscrew the retaining screw and remove the lights switch knob (1).
11 11. Unscrew the lights switch locknut (1) and the starter ring nut (2).
12
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12
SECTION 41 − STEERING − CHAPTER 1
12. Remove all the electrical connections and remove the instrument panel upper guard (1).
13 13. Unscrew the retaining bolts and remove the lower guard (1). (Carry out this operation on both sides).
14 14. Remove the stop ring and remove the hand throttle lever (1) from the plate (2).
15 15. Remove the spring (1) and extract the pin (2) to free the brake pedal. (On both brake pedals).
16 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
13
16. Disconnect the four pipes on the hydrostatic steering control valve.
17 17. Unscrew the hydrostatic steering control and column (1) retaining screws and remove the steering column.
18 18. Remove the hydrostatic steering control (1). 19. To re−fit the hydrostatic steering control valve, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Place the hydrostatic steering control valve in position.
−
Position and secure the steering column.
−
Connect the hydrostatic steering control valve piping.
−
Connect the brake pumps to the control pedals.
−
Connect the throttle lever.
−
Fit the two lower guards.
−
Connect the electrical connections and position the upper guard.
−
Tighten: the starter and lights switch ring nuts.
19
87744428A − 11 − 2007
14
SECTION 41 − STEERING − CHAPTER 1
−
Assemble and secure the lights switch knob.
−
Tighten the indicator lights switch ring nut.
−
Position the fuse box, secure in position and fit the cover.
−
Assemble and secure the handgrip on the throttle lever.
−
Fit the hood on the steering column.
−
Fit the upper guards.
87744428A − 11 − 2007
−
Carry out operation 55 418 10 Multi−indicator panel, only installation (see Section 55, Chapter 7).
−
Carry out operation 41 204 10 Hydrostatic steering wheel, only installation (see page 9).
−
Carry out operation 90 100 84 Bonnet guard, only installation (see Section 90).
−
Carry out operation 90 100 22 Bonnet, only installation (see Section 90).
SECTION 41 − STEERING − CHAPTER 1
15
Op. 41 204 34 HYDROSTATIC STEERING CONTROL VALVE Disassembly − Assembly (with control valve removed) To disassemble the hydrostatic steering control valve, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
24701
20 1. Remove the cover retaining bolts. 2. Remove the cover by sliding to the side.
24702
21 3. Remove the rotor fixed ring, the rotor and the inner spacer.
4. Remove the two O−ring seals on the rotor fixed ring.
24703
22 5. Extract the rotor drive shaft.
24704
23
87744428A − 11 − 2007
16
SECTION 41 − STEERING − CHAPTER 1
6. Extract the thrust washer.
24705
24 7. Remove the threaded plug on the non−return valve seat.
24706
25 8. Extract the O−ring seal from the control valve body.
24707
26 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
27 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
17
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
28 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
29 13. Extract the valve−sleeve trim pin.
24711
30 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
31 87744428A − 11 − 2007
18
SECTION 41 − STEERING − CHAPTER 1
14. Extract the rotary valve from the valve seat sleeve.
24713
32 15. Remove the springs from the neutral position, extracting them from their seats.
24714
33 16. Remove the dust seal and the O−ring seal from their seats in the control valve body.
20428
34 17. Using a 0.2362 in. (6 mm) Allen wrench, remove the threaded plugs from the cylinder safety valves.
20429
35 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
19
18. Remove the seal washers.
27857
36 19. Using a 0.2362 in. (6 mm) Allen wrench, remove the threaded plugs from the cylinder safety valves.
27858
37 20. Turn the control valve body over, extract the springs and the balls from the two cylinder safety valves.
20432
38 Cylinder safety valves components (order of disassembly−assembly). 1. 2. 3. 4. 5.
1
Cylinder safety valve ball. Pressure spring. Calibration adjuster screw. Seal. Blanking plug.
2
3
4
5
25790
39 87744428A − 11 − 2007
20
SECTION 41 − STEERING − CHAPTER 1
21. Using a 0.2362 in. (6 mm) Allen wrench, remove the threaded plug on the pressure relief valve and extract the washer.
20434
40 22. Remove the pressure relief valve adjuster screw.
27859
41 23. Turn the control valve body over and complete disassembly by extracting the spring and the pressure relief valve piston.
20436
42 Pressure relief valve components (order of disassembly−assembly). 1. 2. 3. 4. 5.
1
Pressure relief valve. Pressure spring. Calibration adjuster screw. Seal. Blanking plug.
2
3
4
5
27099
43 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
21
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 re−fitting, 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
44 29. Use tool 380000306 to insert the flat and curved springs (12, fig. 3). Diagram for fitting springs (12, fig. 3 neutral position).
24728
45 30. After inserting the springs in the seat, align and centre (as shown in the drawing).
24729
46
87744428A − 11 − 2007
22
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
47 32. Insert the sleeve−rotor drive shaft trim pin.
24731
48 33. Fit the thrust bearing, following the order and indications shown in the drawing below.
24732
49 1. 2. 3. 4. 5.
Bearing external ring. Thrust bearing. Bearing internal ring with bevel facing contact surface of part (5). Rotating valve. Rotating valve seat sleeve.
1 2 3 4 5 24733
50 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
23
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.
1 24734
51 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.
1
24735A
52 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
53 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
54
87744428A − 11 − 2007
24
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 control valve body when the tapered part of the shaft (2) is released from the seal (3).
27825
55 44. Insert the parts that were previously fitted in operations 26 to 31, 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
56 45. Press the rotating valve so as to bring the thrust bearing into contact with the control valve body.
27826
57 46. Rotate the control valve body and insert the non− return valve ball into the seat indicated by the arrow.
24741
58 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
25
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
59 48. Insert the non−return valve balls into the two seats indicated by the arrows.
27861
60 49. Insert the springs on the backflow valve pins.
27862
61 50. Position the pins, complete with springs, in the backflow valve seats.
27863
62 87744428A − 11 − 2007
26
SECTION 41 − STEERING − CHAPTER 1
51. Lubricate the O−ring seal and insert in the seat on the control valve body.
24746
63 52. Fit the thrust washer, so that the holes coincide with the holes on the control valve body.
24748
64 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.
1
2
24748
65 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. 65) and the trim pin installed on the sleeve.
24749
66 87744428A − 11 − 2007
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 66 with the centre line of one compartment on the rotor.
27
1
24750
67 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
68 57. Fit the cover aligning the retaining holes with those present on the rotor fixed ring.
24753
69 58. Remove retaining tool 380000307 and fit the special screw and washer in the non−return valve seat, shown in the drawing.
24754
70 87744428A − 11 − 2007
28
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
71 60. Turn over the control valve body and insert (see component details in fig. 43) the pressure relief valve piston in the seat indicated in the drawing.
24756
72 61. Insert the pressure relief valve spring.
24757
73 62. Using an 0.3149 in. (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
74 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
63. Tighten plug (2) with the relative seal, using an 0.3149 in. (8 mm) Allen wrench, tightening to the prescribed torque value of 40 to 60 Nm (4.1 to 6.1 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. 79).
29
1 2
25789
75 65. Insert the springs (2, fig. 79) in the cylinder safety valve seats.
27865
76 66. Using a 0.2362 in. (6 mm) Allen wrench, tighten the two cylinder safety valve calibration adjuster bolts (3, fig. 79). NOTE: calibration will be carried out on the workbench or on the tractor to the values shown in the table on page 2.
20475
77 67. Tighten the two plugs (5, fig. 79) and the relative seals (4) using a 0.2362 in. (6 mm) Allen wrench. Once calibration is completed, tighten to the prescribed torque value of 30 Nm (3 kgm).
20429
78 87744428A − 11 − 2007
30
SECTION 41 − STEERING − CHAPTER 1
Cylinder safety valves components (order of assembly). 1. 2. 3. 4. 5.
1
2
3
4
5
Cylinder safety valve ball. Pressure spring. Calibration adjuster screw. Seal. Blanking plug.
25790
79 68. When the unit has been assembled, insert the dust seal in the seat in the control valve body.
24764
80
87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1 Op. 41 204 38 HYDROSTATIC STEERING CONTROL VALVE
1
Bench testing A − CHECKING ROTATING VALVE WEAR 1. Make the connections shown in the diagram in fig. 83 and complete the circuit as in fig. 81. Using the splined drive shaft (1, fig. 82) 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 allowing the valve to intervene. 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 . . . . . . . . . . . . . . . . 140 _F (60 _C) Hydraulic pump capacity . . . . . . in.3/min 732.3054 (l/min 12) Electric motor speed . . . . . . . . . . . . . . . . . 1450 rpm
1
31
7 6
2
5 3
24911
4 81
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”.
2
3
5 4 24912
82 Installation diagram of equipment for testing the rotating valve, seals and for pressure relief valve calibration. 4. Restriction. 1. Splined control shaft. 5. Pressure adjustment handwheel. 2. Torque wrench. 3. Delivery.
87744428A − 11 − 2007
32
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. 82) 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 fig. 82) and complete the circuit, as in fig. 81). 2. Using the drive shaft (1, fig. 82) simulate a turn (to the left or to the right) so as to interrupt the oil flow to the discharge. 3. Gradually increase the in the circuit by turning the handwheel (5), and check on the pressure gauge that the pressure relief valve (24, fig. 3) is activated 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. 82, and complete the circuit as in the drawing 83. 2. Using the drive shaft (1, fig. 82), 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 in fig. 82 and complete the circuit as in fig. 84. Proceed in the same manner as described above, by simply reversing the direction of rotation of the drive shaft (1).
1 1
2 2
3
25800
25799
83 Cylinder safety valve calibration for steering to the left 1. From delivery line − 2. To the restriction − 3. Exhaust.
87744428A − 11 − 2007
3 84
Cylinder safety valve calibration for steering to the right 1. From delivery line − 2. To the restriction − 3. Exhaust.
SECTION 41 − STEERING − CHAPTER 1
33
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. 122 °F (50 °C).
2. Switch off the engine and detach the oil delivery pipe union (1) on the hydraulic cylinder (2).
27151
85 1. 2. 3.
3. Replace the original union with unions (4 and 3), and connect the pressure gauge (5) with a scale of 0 to 150 kg/cm2 with 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 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.
87744428A − 11 − 2007
34
SECTION 41 − STEERING − CHAPTER 1
Op. 41 216 10 STEERING CONTROL CYLINDER Removal − Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
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).
86
2. Disconnect the steering cylinder control pipes (1 and 3) and unscrew the union (2).
87 3. Unscrew the ring nut (1) fastening the steering control cylinder to the front axle.
88
87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
35
4. Levering with a crowbar between the union (1) and the axle body, extract the steering control cylinder (2). 5. To install the steering control cylinder, proceed as follows.
CAUTION Always use appropriate tools to align fixing 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 alignment of the leading wheels (see Section 25, Chapter 2, page 39).
89
87744428A − 11 − 2007
36
SECTION 41 − STEERING − CHAPTER 1
Op. 41 216 18 STEERING CONTROL CYLINDER Disassembly − Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Remove the circlip (1). 90 2. Push the ring (1) with the seals into the cylinder.
91 3. Remove retaining ring (1).
92 4. Extract the shaft (2) with the seal holder ring (1).
93 87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
37
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.
CAUTION Always use appropriate tools to align fixing 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.
94
87744428A − 11 − 2007
38
87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 1
SECTION 41 − STEERING − CHAPTER 2
1
SECTION 41 − STEERING Chapter 2 − Non−stop flow gear pump CONTENTS Operation
41 206 20
Description Page Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Torque settings − Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . see Lift − Chapter 1 Section 35 Hydrostatic steering oil pump D.A. (With the pump removed) . . . . . . . . . . . . . . . . . . . . . . . . 3
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 25
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
gear type with oil suction from rear transmission casing
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . in.3/min (l/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . in.3/min (l/min)
on right−hand side of engine A 25 NEW HOLLAND driven by engine shaft anticlockwise 1:1.08 2484 1720.3074 (28.19) 692.6389 (11.35)
Diameter of driven and driving gear shafts . . . . . . . . . . . . Internal diameter of seats in supports . . . . . . . . . . . . . . . . Clearance between gear shafts and seats on supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . − maximum clearance due to wear . . . . . . . . . . . . . . . . . . .
in. (mm) in. (mm)
0.6850 to 0.6857 (17.400 to 17.418) 0.6870 to 0.6877 (17.450 to 17.470)
in. (mm) in. (mm)
0.0012 to 0.0027 (0.032 to 0.070) 0.0039 (0.1)
Radial clearance of gears in pump body . . . . . . . . . . . . . . maximum wear on pump body, suction side at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0.0007 to 0.0025 (0.020 to 0.064)
in. (mm) in. (mm) in. (mm)
0.0039 (0.1) 0.7213 to 0.7223 (18.323 to 18.348) 0.7793 to 0.7799 (19.796 to 19.812)
Width of pump body for gear seats and supports . . . . . . in. (mm) Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . in. (mm)
2.2862 to 2.2882 (58.072 to 58.122) 0.0039 to 0.0078 (0.100 to 0.200)
87744428A − 11 − 2007
2
SECTION 41 − STEERING − CHAPTER 2
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ MAIN SPECIFICATIONS OF HYDRAULIC PUMP A 31 XRP2
Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Rated output at 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Start of flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm Flow control output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (I/min) Diameter of driven and driving gear shafts . . . . . . . . . . . . Internal diameter of seats in supports . . . . . . . . . . . . . . . . Clearance between gear shafts and seats . . . . . . . . . . . . − maximum clearance due to wear . . . . . . . . . . . . . . . . . .
in. in. in. in.
(mm) (mm) (mm) (mm)
gear type with incorporated regulated output, oil suction from rear transmission casing. on right−hand side of engine A 31 XRP 2 NEW HOLLAND driven by engine shaft anticlockwise 1 : 1.08 2484 2121.8549 (34.77) 854.3563 (14) 1216 1098.4581 to 1342.5599 (18 to 22)
0.6850 to 0.6857 (17.400 to 17.418) 0.6870 to 0.6877 (17.450 to 17.470) 0.0012 to 0.0027 (0.032 to 0.070) 0.0039 (0.1)
Radial clearance of gears in pump body . . . . . . . . . . . . . . in. (mm) maximum wear on pump body, suction side at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm)
0.0007 to 0.0025 (0.020 to 0.064)
Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm) Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . in. (mm) Width of pump body for gear seats and supports Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . in. (mm)
0.9448 to 0.9454 (24.000 to 24.015) 0.9641 to 0.9649 (24.490 to 24.510) 2.8793 to 2.8803 (73.135 to 73.160)
0.0039 (0.1)
0.0039 to 0.0070 (0.100 to 0.180)
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
full−flow, with replaceable paper cartridge
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
on pump intake
Tightening torque
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ PARTS TO BE TIGHTENED
Thread
Pump control coupling hub locknut . . . . . . . . . . . . . . . . . . . . . . . . . .
7/16 20 UNF
87744428A − 11 − 2007
Nm
kgm
29
3
SECTION 41 − STEERING − CHAPTER 2
3
25719
1 A 25 pump components 1. 2. 3. 4. 5. 6. 7.
Nut. Lock washer. Circlip. Driving shaft seal. Control side cover. Cover seals. Gear support.
8. 9. 10. 11. 12. 13.
Driven and driving gear shafts. Gear support. Pump body. Front cover. Lock Washer. Bolt.
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4
SECTION 41 − STEERING − CHAPTER 2
25720
2 A 31 XRP 2 pump components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.
Plug. Compression ring. Cursor seat (12). Spring. Washer. Bolt. Plug. Compression ring. Safety ring. Compression ring. Fifth wheel. Cursor. Flow control valve body.
14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25.
Seals (13). Spacer. Cover seals. Pump body. Gear support. Driven and driving gear shafts. Gear support. Control side cover. Driving shaft seal. Circlip. Safety washer. Nut.
DESCRIPTION AND OPERATION The hydraulic pump is of the gear type with spur gears and function with non−stop flow according to the engine rpm. It is fitted on the rear side of the right hand engine support and are driven by a shaft gear unit. The oil is taken from the rear transmission casing, passing through a filter.
87744428A − 11 − 2007
The rear hydraulic pump controls the hydrostatic steering and various services: front and rear differential locks, PTO and brake, 4WD engagement, POWER SHUTTLE. Supplied with a control valve to reduce the quantity of oil sent at high speeds.
SECTION 41 − STEERING − CHAPTER 2
5
A 31 XRP 2 PUMP MODEL OP. 41 206 20 HYDROSTATIC STEERING OIL PUMP Disassembly − Assembly (with the pump removed) Disassembly
CAUTION
2
Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes. Proceed as follows: 1. Remove the bolts (6, fig. 2) and the relative safety washers (5). 2. Remove the nut (25) that secures the sleeve to the pump driving shaft and the safety washer (24). 3. Remove the control side cover (21), the circlip (23) and the seal (22). 4. Mark the parts (17, 18, 19 and 20), in order to re− fit them in the same position, if in good condition. 5. Remove the supports (18 and 20), and gears (19) from the control side cover (21) and the pump body (17). 6. Recover the seals (16 and 14) and the anti−extrusion rings. 7. Remove the plugs (1 and 7) with the relative seals, remove the flow control components from the body (13), i.e.: the cursor seat (3), the cursor (12), the spring (4). Once the parts are removed, proceed as follows: 8. Check that the gear contact surfaces are flat and perpendicular to their supports. Interpose a thin layer of carbon black; small rough spots can be removed using extremely fine and adequately lubricated abrasive paper. 9. Check that the axial play of the gear−support unit in the pump body is 0.0039 to 0.0070 in. (0.100 to 0.180 mm) The distance (2, fig. 3) must be 0.0039 to 0.0070 in. (0.100 to 0.180 mm) less than the distance (1). If necessary, true the flat surfaces involved using lubricated abrasive paper to remove extremely small quantities of material. 10. Clean all constituent parts thoroughly. 11. Replace seals (16 and 22, fig. 2). 12. Lubricate the parts with the same oil as the system.
25227
3 Assembly
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 13. To re−fit the pump carry out operations 7 to 1, in reverse order, referring to fig. 2 and proceeding as follows: to re−fit the pump carry out operations 7 to no. 1; always ensure maximum cleanliness to prevent foreign matter from entering and damaging the pump; fit together the previously marked parts (17, 18, 19 and 20), referring to operation 4, in the original positions; mount the gear supports (18 and 20) in the pump body, positioning as shown in fig. 2; mount the seals (22), on the control side cover (21), facing towards the inside and insert the circlip (23). insert the plastic anti−extrusion rings on the seals (14 and 16), fitting between parts (13) (15) (17) (21), as shown in fig. 2. Fit the washers (5) and tighten the retaining bolts (6); Fit the washer (24) and the locknut (25).
87744428A − 11 − 2007
6
87744428A − 11 − 2007
SECTION 41 − STEERING − CHAPTER 2
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
1
SECTION 44 − AXLES AND WHEELS Chapter 1 − Axles and wheels CONTENTS Section
Description
Page
44 000
Main data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Cross−sectional views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Fault diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
44 101 22
Front axle hub. Disassembly−Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
44 101 30
Front axle. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
44 101 46
Stub axle. Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
44 511 46
Checking the alignment of the leading wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
DATA Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
inverted U−section, telescopic and oscillating at centre
Camber angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
2°, corresponding to approx. 0.5905 (15) for 16” rims
Toe−in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
0 to 0.1968 (0 to 5)
Diameter of stub axle pin (7, fig. 2) at bushings (6) . . . . . . . . . . . .
in. (mm)
1.4945 to 1.4960 (37.961 to 38.000)
Internal diameter of fitted bushings (6) . . . . . . . . . . . . . . . . . . . . . .
”
1.4980 to 1.5015 (38.050 to 38.140) (*)
Clearance between stub axle pin and bushings . . . . . . . . . . . . . . .
”
0.0019 to 0.0070 (0.050 to 0.179)
Diameter of articulation pivot (1, fig. 2) . . . . . . . . . . . . . . . . . . . . . .
in. (mm)
1.4945 to 1.4960 (37.961 to 38.000)
Internal diameter of fitted bushings (2) . . . . . . . . . . . . . . . . . . . . . .
”
1.4980 to 1.5015 (38.050 to 38.140) (*)
Clearance between stub axle pin and relative bushings . . . . . . . .
”
0.0019 to 0.0070 (0.050 to 0.179)
Stub axle articulation
Axle articulation
(continued)
(*) Value to be obtained without refacing.
87744428A − 11 − 2007
2
SECTION 44 − AXLES AND WHEELS − CHAPTER 1 DATA (cont)
Wheel tracks in. (mm) Models
Tyres A
B
C
D
E
F
G
53.1101 (1349)
57.0471 (1449)
60.9841 (1549)
64.9211 (1649)
68.8581 (1749)
72.7951 (1849)
76.7321 (1949)
53.525 (1357)
57.362 (1457)
61.299 (1557)
65.236 (1657)
69.173 (1757)
73.11 (1857)
77.047 (1957)
56.3384 (1431)
60.2754 (1531)
64.2124 (1631)
68.1494 (1731)
465.786 (11831)
76.0234 (1931)
79.9604 (2031)
6.0016 6.5−16 6.50−16 F2 7.50−16 7.50−16 F2 T4040 T4050
9.15L 15 F2 27X9.5−15 HF 11L−15 I1 11L−15 F3 25/10LLX15 25/10LLX15 TT
2WD front wheel track diagram A B C D
G F E
27460
mm 1
87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
3
SECTIONS
1
2
3
4
5
6
7
18
8
9 17 10 14
13
12
16
11
15
25990
4 2 Sectional views of the stub axle, articulation pin and front axle 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.
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). Cup. Bronze thrust ring.
11. 12. 13. 14. 15. 16.
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). 17. Control cylinder fulcrum pin (18). 18. Control cylinder installation position.
87744428A − 11 − 2007
4
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
TIGHTENING TORQUES
C1 − 49 Nm
C2 − 115 Nm C6 − 186 to 206 Nm
C5 − 186 to 206 Nm
C3 − (*)
C5 − 49 to 68.7 Nm
C4 − 186 to 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.
87744428A − 11 − 2007
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
5
C8 − 102 to 123.5 Nm
C9 − 125 to 154.5 Nm
C10 − 29.4 to 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.
87744428A − 11 − 2007
6
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, fig. 3) . . . . . . . . . . . . . . .
M 10 x 1.25
49
5
Nut (C2) securing leading wheel to hub . . . . . . . . . . . . . . . . . . . .
M 18 x 1.5
115
11.7
Nut (C3) for bearing adjustment . . . . . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
(*)
(*)
Nut (C4) for pin securing end of axle . . . . . . . . . . . . . . . . . . . . . .
M 20 x 1.5
186 to 257.7
19 to 26.3
Cover (C5) for wheel hub bearing greasing . . . . . . . . . . . . . . . . .
−
49 to 68.7
5 to 7
Nut (C6) for stub axles left and right−hand levers retaining bolt
M 14 x 1.5
186 to 206
19 to 21
Nut (C7) securing cylinder to fulcrum pin . . . . . . . . . . . . . . . . . . .
M 18 x 1.5
186 to 206
19 to 21
Stub head locknut (C8, fig. 4) for steering transverse tie−rod .
M 16 x 1.5
102 to 123.5
10.4 to 12.6
Locknut (C9) for steering transverse tie−rod . . . . . . . . . . . . . . . .
M 20 x 1
125 to 154.5
12.7 to 15.7
Nut (C10) securing power steering cylinder pipes . . . . . . . . . . . .
−
29.4 to 46.4
3 to 4.75
(*) See operations 12 and 13, page 13.
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.
87744428A − 11 − 2007
List of specific tools required for the various operations described in this Section. 380000237
Wheel lifting hook.
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
7
27855
5 Tool to be made for extracting the front axle articulation pin (to be used with an extracting tool − Stamp tool with No. 50145 − Measurements in mm) Construct in C40 material − Pin 0.1181 x 0.7874 in. (3 x 20 mm).
FAULT DIAGNOSIS Problems Abnormal tyre wear.
Possible Causes 1. Incorrect tyre pressure.
2. Incorrect front wheel toe−in. Poor stability of tractor.
1. Incorrect tyre pressure.
Solutions 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. Correct the toe−in. Inflate the tyres correctly as detailed above.
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8
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
Op. 44 101 22 FRONT AXLE HUB Disassembly−Assembly
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
The wheel hubs can be removed without removing the axle from the tractor. Proceed as follows for each wheel, bearing in mind that the wheel hubs can be removed without removing the axle from the tractor.
25993
1. Lock the rear wheels using suitable chocks.
6
2. Lift the front of the tractor. 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
7 4. Remove the front wheel retaining bolts (1).
24767
8
87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
9
5. Remove the cover (1) for wheel hub bearing greasing.
1 24775
9 6. Remove the wheel hub bearing adjuster nut securing ring (1).
24776
10 7. Using a socket wrench, unscrew the wheel hub bearing adjuster nut.
24777
11 8. Remove the wheel hub (2) and recover the bearings (1 and 3).
1
2
3
24778
12
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10
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
9. Replace worn bearings and faulty seals using suitable extractors and punches.
24780
13 10. Fill the wheel hub with AMBRA GR9. 11. Refit the wheel hub (2) complete with bearings (1 and 3).
1
2
3
24778
14 12. Using a torque wrench, tighten the nut to a torque of 98 Nm (10 kgm), whilst rotating the wheel hub (1) to correctly seat the bearings. 13. Loosen the nut, then tighten again to a torque of 24 to 29 Nm (2.5 to 3 kgm), whilst continuing to rotate the wheel hub.
1
NOTE: The nut must be replaced each time the wheel hub is fitted. 14. Check the rolling torque R, bearing in mind that: R ≤ 0.8 kgm
24779
15
15. Secure the nut (1) by notching. 16. Refit the cover (1, fig. 9) for wheel hub bearing greasing.
24776
16 87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
11
Op. 44 101 30 FRONT AXLE 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. Check that no one is in the vicinity of the load to be lifted.
To totally remove the front axle from the tractor, proceed as follows. 1. Lock the rear wheels using suitable chocks.
25993
2. Lift the front of the tractor.
17
3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
18 4. Remove the front wheel retaining bolts (1).
24767
19
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12
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
5. Disconnect the power steering cylinder (2) hoses (1).
25995
20 6. Remove the axle articulation pin retaining bolt (1).
25996
21 7. Secure the axle by means of a sling (1).
25997
22 8. Extract the axle articulation pin using an extractor tool (1) fitted with adapter 50145 (see fig. 5) and extension.
25998
23 87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
13
9. Remove the axle assembly (1).
1
24772
24 10. To refit the complete axle on the tractor, follow the disassembly procedure in reverse order. Proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
11. Using a bronze punch fit the axle articulation pin (1). 25996
12. Fit the axle articulation pin retaining bolt (1). 25 13. Connect the hoses (1) of the power steering cylinder (2). 14. Fit the front wheels. 15. Remove the support stand. 16. Lower the tractor and remove the sling. 17. Connect the battery negative lead.
25995
26
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14
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
Op. 44 101 46 STUB AXLE Overhaul
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows for each wheel, remembering that the stub axles can be removed without removing the axle from the tractor. 1. Lock the rear wheels using suitable chocks. 2. Lift the front of the tractor.
25993
27 3. Place a mechanical stand (1) under the engine sump and insert a wooden block between the engine sump and the stand.
25994
28 4. Remove the front wheel retaining bolts (1).
24767
29
87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
15
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
30 6. Extract the control lever (1) from the stub axle pin (2).
24783
31 7. Lower the hydraulic jack and remove the stub axle (1).
1 24784
32 8. Unscrew the bolts securing the axle end (1).
33
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16
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
9. Remove the axle end (1).
24786
34 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
35 11. To refit the stub axle, follow the disassembly procedure in reverse order, using a drift to fit the new bushings on the axle ends.
24788
36 12. Fit the axle end (1).
24786
37 87744428A − 11 − 2007
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
17
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
38 14. Fit the stub axle on the axle end. 15. Position the control lever (1) on the stub axle pin (2) and tighten the securing screw.
24783
39
87744428A − 11 − 2007
18
SECTION 44 − AXLES AND WHEELS − CHAPTER 1
Op. 44 511 80 CHECKING THE ALIGNMENT OF THE LEADING WHEELS
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
A
A+X
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
B+0 to 0.1968 in. (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 0.5905 in. (15 mm), for 16” rims, between the top and bottom edges of the rim (fig. a). When driving in a straight line, the wheels must also be parallel to longitudinal axis of the tractor, or have a maximum of 0.1968 in. (5 mm) toe−in at the front, as measured between the edges of the rims.
B 8821
To check the toe−in exactly, proceed as follows: 40 1. Inflate the front tyres to a pressure of 36.25 psi (2.5 bar). 2. Position the steering wheel at the middle of its travel, with one spoke 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 0.1968 in. (5 mm). 6. If necessary, correct the toe−in by adjusting the end of the transverse steering tie−rod.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
1
SECTION 55 − ELECTRICAL SYSTEM
Chapter 1 − Instruments CONTENTS
Section 55100
Description
Page
Analog instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Digital Instrument Cluster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Digital instrument indicator lights panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Transmitters, sensors and switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1 ANALOG INSTRUMENTS
1 1. Tachometer.
4. Hours worked counter.
2. Fuel gauge.
5. LED indicators to signal machine service status.
3. Engine coolant temperature indicator.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
3
INDICATOR LIGHT PANEL
2
INDICATOR AND WARNING LIGHTS The indicator lights on the control panel inform you of the operational condition of the machine. There are 26 indicator lights of various colours. Some of them signal trouble, act promptly when they light up in order to resolve the problem and prevent serious problems with your machine. 1. Sidelights (green)
Lights up when the sidelights are switched on 2. Full beam headlights (blue)
3. Battery cut−off (amber) (variant not for all markets, fitted by the dealer It stays on for 30 seconds with the ignition key on STOP unless the battery is cut off. It switches off within 30 second when the battery is cut off by pressing the specific button.
Lights up when the headlights are switched onto full beam.
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4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
4. Engine oil pressure (red)
The light should go out a few seconds after the engine is started. If the light stays on when the engine is running, stop and find the cause of the problem. When the engine is warmed up and running at minimum revs, with the tractor stationary, the light may illuminate, even if no faults are present. 5. Grid Heater (amber)
The indicator lights up when the grid thermostarter is turned on by the ignition key.
6. Brake fluid level (red)
9. Fuel Level (amber)
The light comes on when the fuel filter is clogged.
10. Engine air cleaner (amber)
The light comes on when the air filter cartridge is partially or totally clogged. 11. Right direction (green)direction
indicator
Flashes at the same time as the right−hand turn indicators. 12. 4 Wheel Drive (green)
Comes on when the fluid drops below ”MIN” level. Periodically check that the light is working properly. With the ignition key on the first position, by pressing the pushbutton on the lid of the brake fluid reservoir, the light should come on.
Lights up when permanent four−wheel drive is selected by means of the relevant push button.
13. Power take−off (amber) 7. Trailer Brake (red)
Comes on, with the engine running, when the brakes are applied with the tractor brakes coupled together for road driving. The light comes on whenever the handbrake is on or when the brake fluid pressure is low.
Lights up when the engine is running and the power take−off is engaged. 14. Indicator not active
15. Hand Brake (red)
ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ
8. Indicator (amber) Fuel level
The light comes on when the tractor needs refuelling. See Sect. 00 for the fuel tank capacity.
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Indicates that the handbrake is on (with starter key inserted)
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
16. Power steering oil pressure (red)
The light should go out a few seconds after the engine is started. With the engine running at minimum revs and the tractor stationary, the light may come on without indicating a problem.
5
19. Left direction (green)
indicator
Flashes at the same time as the left−hand turn indicators.
20. Abnormal battery charging system operation (red) 17. Second trailer indicator (green)
direction
Flashes at the same time as the tractor turn indicators, if connected. 18. First trailer direction indicator (green)
It should go out once the engine starts. If the light stays on when the engine is running, stop and find the cause of the problem. May light up when the engine is idling, but does not necessarily indicate a fault.
Flashes at the same time as the tractor turn indicators, if connected.
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6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
SPEEDOMETER/TACHOMETER This shows engine rpm and total time to a maximum of six digits: the figures on the black background total the working hours and those on the red background (to the extreme right) tenths of an hour. The green and blue sectors show the number of engine rpm required to reach standard power take−off speed, respectively 540, 540 E and 1000 rpm. −
Green mark = PTO at 540 rpm.
−
Blue mark = PTO at 540 E and 1000 rpm. 3
Engine coolant temperature gauge. −
Green area = normal temperature.
−
White area = temperature too low.
− Red area = engine overheating. In this case, slow the engine to idling speed (without stopping the engine) and, if the light stays on, have the cooling system checked.
4
Fuel gauge
Shows fuel level in the tank. When the tank is full, the pointer moves completely to the right. When the fuel level falls below 1/4, the needle moves into the red area
5
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
7
DIGITAL INSTRUMENT PANEL
6 1. Left digital display − Shows tractor&apos;s speed in km/h/MPH.
your
4. Fuel level bar gauge .
2. Information display − The display shows information on the operational condition of the machine in the form of symbols or code numbers.
5. Warning and indicator lights.
3. Right digital display − The display shows the following information:
6. Speedometer/tachometer.
−
rpm of the front PTO, where applicable, or of the rear one.
7. Engine coolant temperature bar gauge.
−
Clock function.
−
position of the front lift, where applicable, or of the rear one.
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8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1 DIGITAL INSTRUMENT PANEL
1.
Warning stopping
light
(red)
for
If the red ”Stop” warning light comes on, switch off the tractor immediately and look for the cause. A warning symbol will appear on the display confirming the location of the fault.
2. Indicator Lamp (amber)
7 3. Abnormal battery charging system operation (red)
It should go out once the engine starts. If the light stays on when the engine is running, stop and find the cause of the problem.
ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ
4. Indicator (amber) Fuel level
Indicator Lamp (amber) − This indicator light comes on and the display shows a warning symbol. The warning light blinks for 4 seconds, after which the symbol on the display disappears and the light stays on steady. To display the fault, you need to go to the menu. Stop the tractor and investigate the cause of the trouble.
87744428A − 11 − 2007
The light comes on when the tractor needs refuelling. See Section 00 for the fuel tank capacity.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
5. 4 Wheel Drive (green)
Lights up when front−wheel drive is engaged automatically. 6. Automatic four−wheel drive (green) Lights up when four−wheel drive is engaged automatically by means of the relevant push−button. 7. Power take−off (amber)
Lights up when the engine is running and the power take−off is engaged. 8. High (HI) ranges (green)
Lights up when the high gear range is selected (transmission with Power−Shuttle/Dual Command (2 Speed Power Shift)).
9
12. Right direction (green)
indicator
Flashes at the same time as the right−hand turn lamps. 13. Left direction indicator (green)
Flashes at the same time as the left−hand turn indicators. 14. Engine oil pressure (red)
The light should go out a few seconds after the engine is started. If the light stays on when the engine is running, stop and find the cause of the problem. When the engine is warmed up and running at minimum revs, with the tractor stationary, the light may illuminate, even if no faults are present.
15. Trailer Brake (red) 9. Front Lift (amber)
Lights up when the front lift unit is disabled, or lights up briefly when the engine is started (even if the tractor is not fitted with a front lift).
Comes on, with the engine running, when the brakes are applied with the tractor brakes coupled together for road driving. The light comes on whenever the handbrake is on or when the brake fluid pressure is low.
10. Front power take−off (amber) 16. Indicator not active Lights up with the engine running when the front power take−off is engaged (if fitted).
ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ
17. Hand Brake (red)
11. Differential lock (amber)
Comes on to indicate that the differential lock is engaged.
Indicates that the handbrake is on (with starter key inserted). It blinks with the ignition key on STOP and the handbrake disengaged.
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10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
18. Battery cut−off (amber) (variant not for all markets, fitted by the dealer It stays on for 30 seconds with the ignition key on STOP unless the battery is cut off. It switches off within 30 second when the battery is cut off by pressing the specific button.
19. Thermostarter (Grid Heater) indicator (amber) The indicator lights up when the grid thermostarter is turned on by the ignition key.
22. Second trailer indicator (green)
direction
Flashes at the same time as the tractor turn indicators, if connected.
23. First trailer direction indicator (green) Flashes at the same time as the tractor turn indicators, if connected.
20. Full beam headlights (blue) 24. Work Lamps (amber) Lights up when the headlights are switched onto full beam. 21. Sidelights (green)
Lights up when the sidelights are switched on
87744428A − 11 − 2007
Lights up when the working lights are switched on (cab models only)
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
11
Rev counter/hourmeter (1) The engine rev counter. To obtain the engine rpm, multiply the number indicated by the pointer by 100.
Digital display (2) On switching on the engine, the digital display automatically goes into tractor speed mode in km/h or in MPH depending on the setting made.
Digital display (3) The digital display can give the operator different information:
8
25. rear PTO speed (displayed automatically on starting the engine); 26. front PTO speed (if fitted); 27. clock; 28. rear lift position; 29. front lift position (if fitted).
Engine coolant temperature gauge. 1. Red area = engine overheating (the temperature exceeds 100 0C). In this case, slow the engine to idling speed (without stopping the engine) and, if the light stays on, have the cooling system checked. 2. Green area = normal temperature (temperatures between 60 0C and 100 0C). 3. Blue area = temperature too low (temperatures between 40 0C and 60 0C). 9 Fuel gauge. Shows fuel level in the tank. When the tank is full, all the sectors are illuminated. Whereas, when the last two sectors at the bottom (1) remain illuminated, the fuel level is less than 1/4.
10
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12
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
MULTIFUNCTION DISPLAY The multifunction liquid crystal display (1) can show useful and necessary information when driving and a menu for making the following adjustments: 1. 2. 3. 4. 5. 6.
tractor speed calibration; instrument brightness control; sound level on/off on pressing the buttons; unit of measurement in km/h or MPH; setting the clock and 12/24 hour format; fault codes display. 11
The menu is navigated through by using the toggle switches (1 and 2) Each button provides two controls, depending on the position where it is pressed To enter the SETUP MENU you need to turn the ignition key onto position (B) or (C), and hold down switch (1) in position (B) for more than three seconds.
12
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
13
TRANSMITTERS, SENSORS AND SWITCHES
MPH1950A
13
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14
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
TRANSMITTERS, SENSORS AND SWITCHES
MPH1954A
14
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
15
TRANSMITTERS, SENSORS AND SWITCHES
MPH1955A
15
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16
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
TRANSMITTERS, SENSORS AND SWITCHES
MPH1956A
16
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
17
TRANSMITTERS, SENSORS AND SWITCHES A. TRAILER BRAKE SAFETY PRESSURE SWITCH. Activates when the trailer brake pressure circuit drops below 43.5 psi (3 bar). The warning lamp lights up. B. BRAKE LIGHTS SWITCHES. Activates when the brakes are applied. C. ENGINE OIL PRESSURE SWITCH. Activates when the engine oil pressure drops below 9.86 psi (0.68 bar). The warning lamp lights up. D. ALTERNATOR. Provides a square wave signal and recharges the battery. The alternator also provides power for the electrical devices on the tractor. E. AIR FILTER CLOGGED SENSOR. Activates when the vacuum in the air intake system exceeds a pre−stabilised value. The warning lamp lights up. F. PARKING BRAKE SWITCH. The switch closes when the parking brake is applied. G. TRAILER BRAKE INDICATOR SWITCH. Activates when the trailer brakes are applied. The warning lamp lights up. H. GEARS IN NEUTRAL SWITCH. Indicates when the gears are in neutral. I.
ENGINE COOLANT TEMPERATURE SENSOR. The temperature transmitter resistance varies in proportion to the coolant temperature, generating a modulated voltage signal that is measured by the instrument.
J. REAR PTO INDICATOR SWITCH. Activates when the PTO is engaged and enables starting when it is not. K. FUEL LEVEL TRANSMITTER. The transmitter potentiometer provides a signal that determines the level in the fuel tank. The level is shown on the gauge. L. 4 WD INDICATOR SWITCH. Activates when there is no oil pressure in the 4 WD control lines. The warning lamp lights up. M. BRAKE OIL LEVEL SWITCH. Activates when the brake fluid drops below the minimum level. The warning lamp lights up. N. G1 GEAR SWITCH (North American version). Indicates the range position. O. C1 GEAR SWITCH (North American version). Indicates the gear engaged (located in front of the G1 switch). P. SPEED SENSOR (North American version). Indicates the theoretical tractor ground speed. Q. TRANSMISSION OIL TEMPERATURE SENSOR. Indicates the oil temperature in the transmission unit. R. STARTING ADVANCE THERMOMETRIC CUT−OUT SWITCH.
87744428A − 11 − 2007
18
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
MAINTENANCE Front work lights lamp bulb replacement (Fig. 17)
WARNING When handling halogen bulbs, only touch the metal parts, never the bulb. If the bulb comes into contact with your fingers, the intensity of the light emitted will be reduced, adversely affecting its service life. In the event of contact, clean the bulb with a cloth soaked in alcohol and leave to dry. To change the bulbs of the front lights, proceed as follows: 1. Pull the lever (1, fig. 17) to open the bonnet. 2. Lift the bonnet from the front and let it rise up.
17
3. Extract the connection (2, fig. 18). 4. Remove the rubber guard (1, fig. 18) to get to the halogen lamp; then change it with a new one of the same power (55/60 W).
18 Changing swivel work light bulbs To change the lamp bulbs, proceed as follows: 1. Extract the connection (1). 2. Turn the lamp (2) clockwise. 3. Extract it and change it with a new one of the same power (60 W).
19
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
19
Front sidelight and direction indicator lamp bulb replacement To change the lamp bulbs, proceed as follows: 1. Unscrew the two screws (1) on the transparent cover. 2. To extract the lamp bulbs, press them inwards and turn them anticlockwise. 3. Change them with bulbs of the same power: − direction indicators (21 W) − side/tail lights (5 W). 1 MPF0512A
20 Tail light, brake light and direction indicator lamp bulb replacement To change the bulbs, proceed as follows: 1. Unscrew the four bolts (1) securing the transparent cover of the tail light. 1
MPF0510A
21 2. To extract the lamp bulbs (1), press them inwards and turn them anticlockwise. 3. Change the blown bulb with a new one of the same power, bearing in mind that: − side light (5 W) (top) − direction indicator light (21 W) (middle) − brake light (21 W) (bottom).
1
MPF0509A
22 Number plate light bulb replacement Proceed as follows: 1. Pull the black rubber cover (1) outwards to access the lamp. 2. Take out the bulb (2) and change it with a new one of the same power (5 W).
1 2
MPF0511A
23
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20
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 1
Work light bulb replacement To replace the bulb, proceed as follows: 1. Pull back the rubber guard (2). 2. Remove the transparent cover (1). 3. Press the bulb (3) in and twist anticlockwise to remove. 4. Replace the bulb with a new one of the same power (35 W).
24
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 2 − Starting system CONTENTS Section
Description
Page
55 000
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 System testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 201 50
Starter motor. Removal−Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
55 201 54
Starter motor. Removal − Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Bench testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
TECHNICAL DATA CHARACTERISTICS Starter motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TYPE OF STARTER MOTOR Iskra AZF 4591
Power (kW) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4,2
Direction of rotation (pinion side view) . . . . . . . . . . . .
clockwise
Maximum armature shaft end float (mm) . . . . . . . . . .
0,1 B 0,4
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2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
DESCRIPTION AND OPERATION The type of starting system installed depends on the type of gearbox fitted on the tractor. All systems consist of an ignition key−switch, heavy−duty wiring, a starter motor with an electromagnet, a starter relay and gear, range gear and PTO control lever switches. These are the basic circuit components used on models with a mechanical gearbox. More sophisticated systems incorporate other components, which ensure that the engine can only be started in the correct conditions. A 2.5 kW starter motor is series installed. This motor has four poles, four brushes with integrated electromagnet and positive mesh engagement control. The electromagnet consists of two parallel−connected coils. The low resistance intake coil is grounded via the engine, whilst the high resistance hold coil is grounded via the electromagnet body. When the key−switch contact is closed (with the gear and range gear in neutral and the PTO disengaged) the coils are energised 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
87744428A − 11 − 2007
gear, the plunger closes 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 by−passed, 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 the rim gear. When this happens, a clutch spring compresses the pinion, forcing it to connect completely as soon as the starter motor starts turning. 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.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
3
FAULT DIAGNOSIS The engine does not turn over when the starter key is turned, with gears and range gears in neutral and PTO disengaged.
Is the battery fully charged?
Re−charge or replace the battery. Is the engine rotating correctly?
NO YES
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
Repair the wiring accordingly.
NO
Has the engine seized?
YES
NO
Find the cause of engine failure.
Turn the starter key: is a value of +12V measured on the starter solenoid valve input wire (red and black striped wire)?
Has the solenoid valve triggered?
YES
NO
YES
The coils or brushes are probably faulty, or mechanically damaged.
NO
The solenoid valve is probably faulty, remove the motor and check. Check the starter relay: does the relay work when the starter key is turned?
Replace the relay.
NO
YES
Remove the connector from the relay: is a value of +12V measured at pin 30 (red and black striped wire) when the starter key is turned?
YES
NO
Check the reverser lever, gear and range gear switches and PTO lever: are the wires connected?
NO
Replace the relay.
Reconnect the wire to the switch.
YES
Check the operation and condition of all switches.
Replace the switch.
NO
YES
Does the instrument panel display light up when the starter key is turned? YES
Check the starter key−switch: if the wire is connected and in good condition, replace the switch.
NO
Check that the battery main power supplies the key−switch (pin 30).
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4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
SYSTEM TESTING 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 has not seized.
Current absorbed on the starter motor circuit (Fig. 1)
5
1
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 lead on the voltmeter (2) to the battery positive terminal and the negative lead to the battery negative terminal.
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4
3
2
26630
1
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
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 A. •
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.
Starting system circuit resistance (voltage drop) (fig. 2) If the voltage absorption value is too high, check the individual circuit components to find the cause of the voltage drop. IMPORTANT: Disconnect the injection pump shut− off solenoid valve wire.
Positive battery cable
2
1
1. Connect the positive lead on the voltmeter (1) to the positive terminal on the battery (2).
V
2. Connect the negative lead on the voltmeter to the starter motor electromagnet terminal (3).
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
2
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6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
Starter motor ground connections (Fig. 3)
1
2
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.
3
26632
3
Battery ground lead (Fig. 4)
1
2
V
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.
3 26633
4
Op. 55 201 50 STARTER MOTOR Removal and installation (Fig. 5)
1. Disconnect the battery negative cable. 2. Remove the plastic guard (3) on the terminals. 3. Unscrew the nut and remove the power and emergency switch terminal (4). 4. Extract the three retaining bolts (2) on the starter motor (1). 5. To reassemble the starter motor, carry out the removal operations in reverse.
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26633
5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
7
26635
6 Starter motor components 1. 2. 3. 4. 5. 6.
Electromagnet Electromagnet nuts Bolt and stud assembly Control side support Lever Reducer
OVERHAUL OP. 55 201 54 STARTER MOTOR. REMOVAL − DISASSEMBLY Refer to figure 6. 1. Position the starter motor in a vice with padded jaws.
7. 8. 9. 10. 11.
Field coils and casing Brush holder Brush plate Armature Coupler
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.
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8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
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 “C” 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 do not require replacement during the entire 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 re-
87744428A − 11 − 2007
moving 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.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2 Starter motor test (without load) (Fig. 7) NOTE: A fully charged battery and a battery/starting tester (high discharge rate tester) with a carbon battery (variable load resistance) are required to carry out this test.
6
9
7 1
5
2
1. Position the starter motor in a vice with padded jaws. 2. Connect the negative cable on the battery (4) to the starter motor assembly flange. 3. Using a short cable, make a bridge (7) between the electromagnet contacts (6).
3
4 26636
7
4. Connect the positive lead on a voltmeter (3) to the positive terminal on the battery (4) and the negative lead to the negative terminal on the battery. Connect the positive lead on the ammeter(1) to the positive terminal on the battery (4) and the negative lead to the battery or the starter motor terminal. 5. Position a manual tachometer (5) on the end of the armature shaft. The maximum power absorption, which is a specific value for each starter motor, must be within the range of values shown on the TECHNICAL DATA table. Adjust the carbon battery voltage (2) and the armature rpm to the values shown on the table. 6. If the starter motor does not work according to the technical data specifications, check to see if the field coils are grounded, the armature scrapes or if the armature shaft is deformed.
BENCH TESTS
1
ARMATURE (Fig. 8) 1. The switch surface must be clean and not burnt. If necessary, remove the burn stains with fine sandpaper − not emery cloth. Finally, clean the switch with a cloth soaked in kerosene. 2. If the switch needs re−facing, make sure that the diameter is not below the minimum value prescribed in the TECHNICAL DATA table. After re− facing, the switch must be polished with fine sandpaper and cleaned with a cloth soaked in kerosene.
26637
8
NOTE: Do not cut the armature metal when making insulation slots.
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10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 2
3. Armature insulation can be checked by connecting an ohmmeter (1) between switch segments and the armature shaft. This reading should show infinity, i.e.: there should be no continuity. 4. To test for short circuits in the armature, use a suitable test instrument or, as the only alternative, try replacing the armature. 5. If the armature circumference has obviously made contact with the pole pieces, the pole bearings are probably too worn. First check that the pole pieces are fixed and that the armature rotates correctly in a lathe. If necessary, replace the armature bearings.
Field coils 1. To test the field coils insulation, connect an ohmmeter to each of the coil brushes in turn and to a clean and unpainted area of the casing. No readings should be taken, i.e.: there should be no continuity. 2. To test the field coils continuity, connect an ohmmeter to each of the coil brushes in turn and to the main power terminal (the biggest braided cable). The reading should be 1 W. 3. If there is a fault in the field coils, replace the entire box and field coils system.
Bearing bushings 1. Check if the bushing on the brush plate and the box on the drive pinion side are worn. Assemble the armature shaft and note play. Replace the bushings if end float is excessive. Check the field poles to see if there are any signs of scraping against the casing. This could also be caused by worn bushings.
Drive pinion 1. Check roller clutch operation. The pinion must only rotate clockwise. If the pinion is either locked or spins in both directions, or if the pinion teeth are damaged, assemble a new control unit. If there is clear evidence of damage to pinion teeth, check flywheel rim gear, as described in Section 10.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 3 − Charging system CONTENTS Section
Description
Page
55 000
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Tightening torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 System testing and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
55 301 10
Alternator. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
55 301 12
Alternator. Disassembly − Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
TECHNICAL DATA TYPE OF ALTERNATOR CHARACTERISTICS ISKRA Polarity
Grounded negative
Direction of rotation (pulley side)
Clockwise
Rated voltage (V)
14
Maximum rotation speed (rpm)
12.000
Maximum output (A)
120
Regulator controlled voltage (V)
14,25B14,75
Inductor coil resistance (W) at 25°C
2,5B2,7
Regulator controlled voltage (V) . . . . . . . . . . . . . . . . .
13.6 to 14
Inductor coil resistance (W) at 77 °F (25 °C) . . . . . . .
3.0 to 3.2
Voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RTT119AC
TIGHTENING TORQUES PARTS TO BE TIGHTENED Pulley retaining nut
Nm 75 B 80
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2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
DESCRIPTION AND OPERATION Description of the alternator Iskra 120 A alternators are 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 V−type driving belt. Alternators are fitted with a built−in regulator. 120 Amp Alternator. 1.
Socket W
2. 3.
Battery connection (B+ terminal) Alternator charge indicator connection (D+ terminal)
87744428A − 11 − 2007
1
2
3 MPH1933A
1
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
3
1
5 2
3
4
26640
2 Alternator charging circuit 1. 2. 3. 4.
Starter switch Alternator charge warning light Battery Alternator electronic voltage regulation circuit
Alternator operation Refer to figure 2. When the starter key is turned, low current passes from the battery through the rotor field wiring. The circuit closes, powering the charge warning light, the alternator D+ terminal, the rotor field winding, the alternator regulator and ground. At this point the warning light illuminates and the rotor is partially magnetised. When the engine starts and the rotor, partially magnetised, turns inside the stator windings and generates three−phase alternating current. A constant quantity of this current is transformed into direct current by three field diodes built into the rectifier. The direct current is then reintroduced into the circuit to increase current flow through the rotor field winding.
5. Alternator B+ : Battery connector D+ : Alternator charge indicator
This action causes a constant increase in the rotor magnetic field and a fast increase of current and voltage output. As the generated voltage output (reflected by D+ terminal) increases, the warning light 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.
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4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
SYSTEM TESTING AND TROUBLESHOOTING Precautions To avoid damaging alternator charging system components, take the following precautions: •
DO NOT 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.
•
1 2
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 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. Battery check 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. Periodically check the alternator driving belt tension. If the belt tension is insufficient, check the belt tensioner as indicated below.
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MPH1934A
3 Fig. 3. Fan belt tensioner 1. 2.
Belt Alternator
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3 Correct deflection values, measured by applying the following loads to the middle of the belt: Load (N) Deflection in. (mm)
5
If the warning light remains on, check that there are no grounded short circuits between the D+ wire endings and the warning light.
78 to 98 0.3937 to 0.433 (10 to 11)
NOTE: If belts are cracked or require frequent adjustment, they must be replaced.
3. Warning light check Turn the ignition key and check the light is completely lit. If the warning light does not illuminate completely, check the light bulb. If the light bulb is in working order, carry out the alternator wire connection tests, as described under the heading “PRELIMINARY TESTS” in this section. If the light is on, start the engine and run it above minimum speed. The warning light should switch off. If the warning light does not go out, stop the engine and disconnect the D+ terminal wire. If the warning light goes out now, one of the alternator components is malfunctioning. Carry out the “ALTERNATOR COMPONENTS TEST”, as described in this section.
Preliminary tests The preliminary tests can be carried out without removing any components from the tractor charging circuit. The tests check: •
the alternator wiring connections
•
the alternator charging current and controlled voltage
•
voltage drops in the alternator charging circuit
•
maximum alternator output
The following testing devices are required: •
0 to 30 V mobile coil voltmeter
•
0 to 1 V millivoltmeter
•
0 to 110 A mobile coil ammeter
•
1.5 Ohm 110 A variable load resistor.
NOTE: Most commercially available testing devices include several devices in the same case. Use these devices according to the manufacturer’s instructions.
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6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
1. Alternator wire connection tests See figure 5. 1. Disconnect battery. 2. Disconnect terminals B+ (2) and D+ (3) on the alternator. 3. Reconnect the battery and turn the starter key to ON, without starting the engine. Connect a voltmeter (4) between each terminal and earth (ground) (1). Voltage must be present at the battery.
26643
If there is no voltage at the battery, find and repair the continuity failure in the external wire circuit. See the circuit diagram in figure 2.
4
4. Connect the D+ terminal warning light (red) to earth (ground). The warning light should switch on. 5. Disconnect the battery and reconnect the previously disconnected connectors to the alternator.
NOTE: If the warning light does not switch on when the wire is reconnected to the alternator, there is a fault either in the alternator regulator or the rotor circuit. Check D+ terminal is clean and then test the alternator components as described in this section.
2. Charging current and regulated voltage tests See figure 6. 1. Make sure that all tractor electrical devices are switched off and that the starter key is in the OFF position. 2. Disconnect the battery negative terminal and the B+ alternator terminal (3). 3. Connect an ammeter (1) between the disconnected wire (red) (4) and the alternator B+ terminal. 26644
4. Connect a voltmeter (2) between the B+ alternator terminal and earth (ground). 5. Reconnect the battery. Start the engine and run at 2000 rpm. Note the readings on the voltmeter and ammeter. The voltmeter readings should be higher than the battery voltage and, when the ammeter value falls below 10 A, the voltmeter reading should stabilise at 13.6 to 14 V.
87744428A − 11 − 2007
5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
7
If the voltmeter reading is higher than 14 V, the alternator regulator must be replaced, as described in this section. (After installing a new regulator, carry out tests 4 and 5). If the voltmeter reading is less than 13.6 V, there is either a faulty component in the alternator or a failure due to excessive resistance in the external charging system connections. If the ammeter indicates zero A, one of the alternator components is faulty. Switch off the engine and carry out alternator components test, as described in this chapter.
3. Charging circuit voltage drop tests (a) Insulated side voltage drop tests Refer to figure 6. Check the ignition key is in OFF position. 1. Disconnect the negative battery cable and the B+ alternator wire (1). 2. Connect a millivoltmeter (5) between the positive battery terminal and the D+ wire (3) (positive side of the wire). 3. Connect an ammeter (2) between the B+ alternator terminal and the D+ wire (negative side of the wire).
26645
6
4. Reconnect the negative battery cable and connect a variable load resistance (4) with the cursor in the minimum current absorption position (maximum resistance) through the battery terminals. 5. Start the engine and increase speed to 2000 rev/min. 6. Gradually increase the resistance charging load (decreasing the resistance) until the ammeter indicates 45 or 65 A, according to the type of alternator. 7. Note the reading on the millivoltmeter, which should not exceed 400 millivolt. Readings higher than 400 millivolt indicates a fault due to excessive resistance on the external circuits. If the alternator cannot produce the requested output and the reading on the millivoltmeter is lower than 400 millivolt, there is a faulty component in the alternator. Carry out the alternator component tests as described in this section. 8. Stop the engine.
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8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
(b) Ground side voltage drop test Refer to figure 7. 1. Check the ignition key is in OFF position. 2. The circuit is the same as that described in the previous test, except that the millivoltmeter (4) is now connected between the negative battery terminal and the alternator casing (negative side of the casing).
NOTE: Make sure that the variable load resistance (3) is in the minimum current absorption position (maximum resistance).
26646
7
3. Start the engine and increase speed to 2000 rpm. 4. Gradually increase the resistance charging load (decreasing the resistance) until the ammeter (2) indicates 45 or 65 A, according to the type of alternator. 5. Note the reading on the millivoltmeter, which should not exceed 200 millivolt. A reading higher than 200 millivolts indicates malfunctioning due to excessive resistance in the external circuits. If the alternator cannot produce the requested output and the reading on the millivoltmeter is lower than 200 millivolt, there is a faulty component in the alternator. Carry out the alternator component tests as described in this section. 6. Stop the engine.
4. Maximum alternator output test Refer to figure 8. 1. Check the ignition key is in OFF position. 2. Disconnect the negative battery cable and the alternator B+ wire (4). 3. Connect an ammeter (5) between the B+ alternator terminal (4) and the D+ wire (1) (negative side of the wire). 4. Connect a voltmeter (3) between the alternator B+ terminal (4) and earth (ground). 5. Reconnect the battery, start the engine and increase speed to 2000 rpm.
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26647
8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
9
6. Gradually increase the resistance charging load (2) (decreasing the resistance) until the ammeter indicates 45 or 65 A, according to the type of alternator. 7. Note that the voltmeter reading does not fall below 13.6 V. Readings of less than 13.6 V indicate the presence of a faulty alternator component. Carry out the alternator component tests as described in this section. Alternator component tests The alternator component tests must only be carried out if the INITIAL CHECKS have shown the presence of a faulty alternator component, allowing the following checks to be performed: • the regulator, • rotor field winding continuity, • rotor brushes, springs and contact rings. NOTE: The previously described component tests can be carried out with the alternator installed on the tractor. In order to carry out the other alternator component tests, remove the alternator from the tractor. See the section REMOVAL, INSTALLATION AND OVERHAUL in this chapter.
OP. 55 301 10 ALTERNATOR. Removal − Installation IMPORTANT: Before disconnecting the alternator wires, make sure that the starter key is in the OFF position − alternator removal. 1. Raise the bonnet. 2. Carry out operation 90 100 80 Protective mesh, only removal of right−hand guard (see Section 90). 3. Disconnect the two wires B+ (1, fig. 10) and D+ (2, fig. 10) from the alternator. 4. Loosen and remove the nut and bolt (3, fig. 10) fastening the alternator to the belt tensioner (4, fig. 10). 5. Move the alternator to slacken the belt (1, fig. 12) tension, then remove from the pulley (2, fig. 12) from the alternator.
9
26648
10
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10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
1
2
3
4
5
6
7
8
10
9
26650
11 1. 2. 3. 4. 5.
Pulley retaining nut Pulley Cooling fan Front support plate Rotor
Alternator Components 6. Stator 7. Rear support plate 8. Rectifier bridge 9. Guard 10. Electric voltage regulator with incorporated brushes
2
1 Alternator pivot (Fig. 12) 1. 2. 3.
Belt Pulley Alternator retaining bolt
3 28011
12 Firmly fix the alternator horizontally to an appropriate holder with internal surfaces protected with soft material. Remove the guard (1) after having unscrewed the alternator retaining nuts (Fig. 13). Before dismantling the alternator completely, carry out the operations and checks described on the following pages.
26651
13
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
11
Rotor and regulator field circuit test The following testing devices are required: • 12 V battery • multi−function tester • 2 watt test lamp. Refer to figure 14. 1. Disconnect all alternator wires. 2. Connect a 12 V battery and a 2.2 watt test lamp (2) in series between D+ (1) and the alternator casing (negative side of casing).
26652
14
3. The test lamp should light up. If the test lamp does not light up, then the rotor circuit is faulty. Check brushes, contact rings and rotor field winding continuity. If the test shows that these components work satisfactorily, then the regulator may be faulty. Checking the continuity of three stator windings
W
Position the points of an ohmmeter (regulated on the W x1 scale) so that they touch the stator phase ends (a − b − c) in the three possible ways shown in figs. 15 − 16 − 17. Each of the three readings should show the same resistance value. If resistance is infinite or zero, the measured phase is either interrupted or short−circuited, therefore the stator will need to be replaced. 26653
15
W
26654
16
87744428A − 11 − 2007
12
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
W
26655
17 Checking the diodes Disconnect the terminal wire connector (1) of the excitation diodes from the positive brush pin (Fig. 18).
26656
18 Unweld stator winding terminals (2) from the rectifier bridge (Fig. 19).
26657
19 Excitation diodes test Insert an ohmmeter point in the connector (1) mentioned above (Fig. 18). The second point must be placed in contact with each of the three terminals (A−B−C). Repeat the three measurements after inverting the instrument points (Fig. 20).
26658
20 87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
13
Positive power diode tests Place an ohmmeter point in contact with the positive (X) alternator terminal and the other successively with each of the three terminals (A−B−C) (Fig. 21). Repeat the three measurements after inverting the instrument point connections.
26659
21 Negative power diode tests Place an ohmmeter point in contact with negative (Y) diode plate and the other successively with each of the three terminals (A−B−C) − (Fig. 22). Repeat the three measurements after inverting the instrument point connections.
26660
22 In the three tests described above, the instrument should show resistance at each terminal (A−B−C). Reversing the instrument point connection, there should be no resistance (Fig. 23). If there is resistance in both cases, then the diodes are short−circuited. Otherwise, with an R = 0 value (interrupted diode), replace the entire rectifier bridge.
ROTOR Check on rotor winding resistance measured between pins connected to brushes Disconnect the excitation diode terminal wire connector (1) from the pin connected to the positive brush. Place both points of an ohmmeter (regulated on a W x 1) in contact with the two voltage regulator− brush holder pins. If the resistance reading is different from the prescribed value, or if it is infinite (interrupted circuit), check and replace the rotor if necessary (Fig. 23).
26661
23
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14
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
OP. 55 301 12 ALTERNATOR, REMOVED Disassembly − Assembly Fit a suitable Allen wrench in the hexagonal hole on the alternator shaft to prevent it from moving. With another wrench unscrew the fan and rotor pulley. Extract these parts, together with the spacers and alternator shaft washers (Fig. 24).
26662
24 Disconnect the excitation diode terminal wire connector (2) from the pin connected to the positive brush. Unscrew the screws (3) securing the electronic voltage regulator (4), complete with brushes, to the rear alternator support. Unscrew the nuts (5) and extract the screws that fasten the alternator main external parts (Fig. 25).
26663
25 Electronic voltage regulator (Fig. 26) A. Brushes B. Plate pins
26664
26 Separate the parts (as illustrated) bearing in mind that a considerable degree of pressure on the rotor shaft is required to free the front support plate (6) and the rotor (7) (Fig. 27). If a press is not available, use a brass drift to avoid damaging the thread.
26665
27 87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
15
Unscrew the screws (9) securing the rectifier bridge (10) to the rear support plate (8) (Fig. 28). The rectifier bridge must not be disassembled, as the spare part is provided complete.
26666
28 Separate the rectifier bridge (10) from the rear support−plate and unweld the stator winding terminals (11) (Fig. 29).
26667
29 Separate the stator (12) and the terminals (11) from the rear support plate (8) (Fig. 30).
26668
30 Inductor winding insulation test Place both points of an ohmmeter (regulated on a W x 1 scale) in contact respectively with a slip ring and the rotor casing (see arrows). The instrument should show infinite resistance. If this is not the case, replace the rotor (Fig. 31).
26669
31 87744428A − 11 − 2007
16
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 3
Check on inductor (rotor) resistance on slip rings Place both points of an ohmmeter (regulated on a W x 1 scale) in contact respectively with the rotor slip rings (see arrows): the instrument should show a certain degree of resistance (Fig. 32). If the resistance reading is different from the prescribed value, or if it is infinite (interrupted circuit), replace the rotor. Check that the bearing rotates freely, without sticking or making noise. Check that the brushes have not dented the rings. If this is the case, replace the whole rotor.
26670
32 Assembly
4
To assemble, reverse the order of the disassembly operations.
2
OVERHAUL 1. Check that the rotor and stator poles are not worn. If this is the case, either the bearings are worn, the boxes are not aligned or the rotor shaft is deformed. NOTE: The alternator bearings cannot be serviced separately, therefore they must both be changed when necessary. 2. Remove the bearing lock (3) plate (2) securing screws (1) then remove the front support plate (4) (Fig. 33). Check for wear and damage and replace, if necessary. Before installing the ball bearing, check the front support plate holder and clean it carefully. 3. Installation of bearing (5) on the support plate side is different from the previous operation. A new rotor and bearing assembly must be fitted. INSTALLATION 1. Refit the alternator by following the removal procedure in reverse. During installation, remember to: • make sure that the negative (ground) battery cable is disconnected from the battery during alternator installation. • regulate the alternator driving belt as previously described in this chapter.
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1 3 26671
33
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 4
1
SECTION 55 − ELECTRICAL SYSTEM Chapter 4 − Battery CONTENTS Section
Description
Page
55 000
Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Description and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
55 301 40
Battery removal − installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Battery checking and maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Battery charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery problems − frequent causes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
TECHNICAL DATA TYPE OF BATTERY CHARACTERISTICS
All Models
Voltage (V) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
Cold start amperage (C.C.A) . . . . . . . . . . . . . . . . . . . .
730
Capacity (Ah) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
88
Number of elements . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
Weight lbs. (kg) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
X 30.87 (X 20)
Grounding terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Negative
DESCRIPTION AND OPERATION A “sealed”, maintenance−free battery is installed in all models, located behind the driving seat. 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. • Controlling the electrical system voltage. • To supply electricity when the power required is higher than that produced by the alternator. • 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 negative plate by means of a porous insulating separator. If one of the positive plates comes into contact with the negative plates in the element, the element will short circuit and be irreparably 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 comprises 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 in polypropylene.
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2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 4
OP. 55 301 40 BATTERY Removal − Installation REMOVAL 100 Ah Battery installed in front of the engine (Figs. 1 and 2) 1. Raise the bonnet. 2. Loosen the bolts on both terminals and disconnect the negative (2) and positive (1) cables from the battery, making sure that they do not touch the battery (Fig. 1).
28004
1
3. Loosen the battery securing bolts on the front side. 4. Using the handles (1), fitted on both ends of the battery, lift and remove the battery from its housing (Fig. 2).
28003
2
INSTALLATION Applicable to all types of battery 1. To re−install the battery follow the removal procedure in reverse, 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) on the terminals; do not use traditional grease lubricants, as these products may favour electrolytic corrosion. • Make sure that the battery housing and support are clean without objects (small stones, etc.) which could pierce the battery casing. • Make sure that the battery terminal polarity is correct and that the terminal connections are suitably tightened. • If a radio is installed, all data stored in the memory will be lost and it 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 BATTERY CHECKING AND MAINTENANCE RELATIVE DENSITY The relative density of the battery electrolyte shows the charge level of the battery. When the battery is fully charged, the relative density of the electrolyte is at least 1.280 to 77 °F (25 °C). Alternatively, the approximate charge status can be measured by using a digital voltmeter (± 0.01V), as follows: Less than 10.5 V battery unusable* Less than 11.8 V Battery flat Less than 12.3 V Battery half−charged More than 12.6 V Battery fully−charged See the notes under the TESTS” heading for instructions on how to recuperate a slightly sulphated battery. The battery voltage must be measured on a flat battery, considering the following: S. The battery must have been flat for at least four hours. T. If the vehicle has been used recently, switch the headlamps on for two minutes. When a battery is flat, the sulphuric acid in the electrolyte combines chemically with the plates and this decreases the relative density of the solution. A battery densimeter will determine the relative density of the electrolyte in an element, and the quantity of sulphuric acid not used in the solution indicates the degree of charge of that element. Low temperatures require a higher battery charge to operate. For example: a battery with a relative density of 1.225 at 80 °F (27 °C) can activate the starter motor at ambient temperatures, but will fail to do so if the temperature drops as a result of poor battery performance levels. Table 1 shows the effect of temperature on battery performance. Table 1 *
Temperature
Fully charged battery performance
77 °F (25.0 °C) 23.9 °F (−4.5 °C) −11.2 °F (−24.0 °C) −17.5 °F (−27.5 °C) −23.8 °F (−31.0 °C) −30.1 °F (−34.5 °C) −35.5 °F (−37.5 °C)
100% 82% 64% 58% 50% 40% 33%
3
Maximum battery life can be achieved by taking care of and regularly checking the battery. The energy capacity output must not be exceeded by a constant/ excessive overload and charging requirements must be respected.
BATTERY MAINTENANCE
CAUTION Batteries contain sulphuric acid and generate a highly explosive hydrogen and oxygen mix during charging. • •
Never use devices that produce flames or sparks whilst checking the electrolyte level. Always protect hands and eyes before removing the battery caps.
During battery maintenance, follow the steps below: 1. Keep the electrolyte at the recommended level of 0.6692 in. (17 mm) over the plates. If this level is not respected, the acid concentration will increase, which could cause damage to the separators and diminish plate performance. 2. Only use distilled or demineralized water, never overfill or use tap/rain water or other sources of water. 3. Keep the battery 75% charged (at least) to avoid plate sulphurisation, performance loss and possible freezing at low temperatures. 4. Avoid overcharging the battery, as excessive charge will generate high internal heat, causing grid deterioration water leaks. 5. During rapid recharging, make sure that the battery temperature does not exceed 122 °F (50 °C). 6. Do not add sulphuric acid to an element unless electrolyte has been spilled. Before topping up, make sure that the solution has the correct relative density. Slow recharge is the only way to recharge the battery completely. Use a high amperage battery charger to charge the battery with high current intensity for short periods of time, but this must be followed by a slow charge to achieve full capacity battery performance.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 4
DRY−CHARGED BATTERIES Dry charged batteries must be prepared as followed: 1. Remove the breather caps from the battery element. 2. Fill each element to the recommended level with electrolyte, at the relative density of 1.260. NOTE: The electrolyte is formed with sulphuric acid, diluted at a temperature of 69.8° to 89.6 °F (21° to 32 °C). 3. After filling, leave the battery to rest for 15 minutes, then check the electrolyte level and top up if required. 4. Charge the battery for 4 hours at 5 to 8 A, making sure that all of the elements are freely producing gas. 5. Refit the breather caps on the battery element.
CHARGING THE BATTERY Before charging a battery: 1. Thoroughly clean the battery casing, the covers on the elements and the terminals with diluted ammonia or warm water. 2. Check the level of the electrolyte in each element and, if found to be under the plate level, top up with distilled water to cover the plates. NORMAL CHARGING (TOP UP) 1. Fully charge the battery using a slow battery charger at 3 to 6 A for the required time. This operation could take 36 hours or more if the battery is extremely flat. A severely sulphured battery may not charge at all. When the battery is completely charged, the elements will produce gas freely and the relative density will remain constant. Disconnect the battery charger after three consecutive densimeter readings taken each hour, to show that the relative density has stopped increasing. 2. When using a rapid or fast ampere charge, follow the manufacturer’s instructions carefully. High charging amperage increases the electrolyte temperature and, if the battery charger is not fitted with an automatic timer or thermostat, this temperature may exceed 122 °F (50 °C), which
87744428A − 11 − 2007
can lead to violent boiling in the battery, thereby damaging the internal components. 3. Re−check the level of the electrolyte in each element and add distilled water as needed.
CAUTION Explosive gas is formed when a battery is charged. Do not smoke or use naked flames when checking the electrolyte level and make sure that the battery charger is switched off before connecting or disconnecting, to avoid sparks that may ignite the gas.
CHARGING EXTREMELY FLAT BATTERIES To recharge a Pb−Ca maintenance−free battery we recommend using a constant voltage battery charger. For extremely flat batteries, charge for 48 hours at 16 V, with current limitation (50A for 100Ah). This method is self−regulating: high current is provided at the beginning (when the battery voltage is very low), whilst current decreases progressively when the battery is fully charged (and the voltage is high). If only constant voltage battery chargers are available, we recommend using the voltage levels and times shown in Table 2. These figures refer to extremely flat batteries. If the battery is only 50% charged, use half the time shown (slow charging programs). For other conditions, reduce charging time proportionally. When feasible, use the slowest charging programme for increased battery life. Table 2 Type of battery 100 Ah (730 dca) Slow charging programs Rapid charging programs (emergency use only)
23 hours at 5a 11.5 hours at 10A 6 hours at 10A
If violent boiling occurs during recharging, due to gas formation or electrolyte leakage, or the battery case is hot (122 °F (50 °C) or more), temporarily reduce or stop battery charging to avoid damaging the battery.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 4 TESTS Before beginning battery tests, check that the breathers are not blocked, there is no rust, the breather caps are not open and the casing is not cracked. Equipment required for testing: • Densimeter • Battery starter tester (high amperage multi− tester) • Thermometer • Battery charger Relative density: This test shows the charge level of the battery. 1. With the float in the vertical position, note the reading. 2. Adjust the densimeter reading for battery electrolyte temperature variations subtracting 4 points (relative density 0.004) for every 41.9 °F (5.5 °C) below the calibrated temperature of the densimeter and adding 4 points (relative density 0.004) for every 41.9 °F (5.5 °C) above this temperature. The following examples have been calculated with a densimeter calibrated at 86 °F (30 °C). Example 1: Temperature lower than 86 °F (30 °C) Electrolyte temperature 66.2 °F (19 °C) Densimeter reading 1.270 Subtract 11.0 x 0.004 5.5 Correct relative density = 1.262 Example 2: Temperature above 86 °F (30 °C) Electrolyte temperature 104 °F (40 °C) Densimeter reading 1.220 Add 10.0 x 0.004 0.007 5.5 Correct relative density = 1.227 3. Use the following table to define the charge level.
Charge level
Correct relative density at 59 °F (15 °C)
Correct relative density at 77 °F (25 °C)
Average battery voltage
100% 75% 50% 25% Flat
1.295 1.253 1.217 1.177 1.137
1.287 1.246 1.210 1.170 1.130
12.66 12.45 12.30 12.00 11.84
NOTE: The relative density should not vary more than 0.025 points between cells.
5
4. If the relative density is 1.280 or more, the battery is fully charged and in good working condition. 5. If the relative density is less than 1.280, charge the battery and check the charging system to determine the cause of the low charge. NOTE: If distilled water has been added recently, recharge the battery for a short time, otherwise the densimeter will not provide precise readings. If the battery has been charged under static conditions, a thicker electrolyte will accumulate at the bottom of the elements. The battery must be shaken at regular intervals in order to mix the electrolyte. This will improve the charging amperage and provide more precise densimeter readings during the tests. Performance test The performance test helps us to understand if the battery can adequately start the engine. Voltage readings show battery condition. Before carrying out the test, check that the electrolyte level is correct and the open circuit voltage is 12.5V or more. The battery can be tested in the tractor or removed. 1. Switch the battery start tester current control to “OFF” (high amperage discharge tester). Calibrate the voltage selection switch to the rated battery voltage, or slightly higher. Connect the positive tester conductors to the positive terminal on the battery and the negative conductors to the negative battery terminal. 2. Turn the current control knob until the ammeter reading reaches half the cold start battery amperage and note the voltage reading. • If the reading shows 9.6 V or more after 15 seconds, the battery has adequate power output and can be easily charged following the normal procedure. • If the reading is below 9.6 V, the battery is not satisfactory for use and must be tested as described below. WARNING: Do not leave high discharge on the battery for more than 15 seconds. Test charge: This test is only for batteries that failed to pass the previously described performance test. 1. Connect the positive battery charger tester conductors (high amperage discharge tester) to the positive battery terminal and the negative conductors to the negative battery terminal. 2. Connect the positive battery charger conductor to the positive battery terminal and the negative conductor to the negative battery terminal.
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6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 4
3. Turn the battery charger timer to more than the “3 minute” charge, and then back to the “3 minute” charge. 4. Set the charging amperage as close as possible to 40 A. 5. After 3 minutes of rapid charging, read the voltmeter. • If the total voltage exceeds 15.5 V, the battery is not satisfactory and is probably sulphured or worn and must be replaced.
4. Grid active material separation.
NOTE: A slightly sulphured battery can be renewed using a multiple−type battery charger, with an upper open circuit voltage limit of 50 V. A sulphated battery has high resistance and for this reason it will be necessary to set a high voltage at the beginning to overcome resistance. At the beginning there may be no visible sign of charging. After a few minutes of inactivity a low charge will be shown, followed by a rapid amperage rise. Amperage must not exceed 14.0 A or the temperature of the electrolyte must not exceed 122 °F (50 °C). When the amperage has stabilised, reset the voltage until the amperage remains fixed at 5 A. Continue at this level until the relative density of the electrolyte stops increasing (approx. 1.275 to 1.280 at 68 °F (20 °C); This may take 48 hours. Let the battery rest for 24 hours and then carry out the previously described performance test.
4. Battery electrolyte freezing. A fully charged battery freezes at −85 °F (−65 °C). A 50% charged battery freezes between 1.4 °F (−17 °C) and −16.6 °F (−27 °C). Completely flat electrolyte freezes at 26.6 °F (−3 °C) to 12.2 °F (−11 °C). Excessively fast charging and boiling caused by gas formation cause the separation of active material from the grids. Separation destroys the battery chemical function.
•
If the total voltage is below 15.5 V, check the relative density of each element and recharge the battery according to the following scale: Relative density
Rapid charge up to:
1.150 or less
60 minutes
from 1.151 to 1.175
45 minutes
from 1.176 to 1.200
30 minutes
from 1.200 to 1.225
15 minutes (slow charge only)
BATTERY PROBLEMS − FREQUENT CAUSES 1. Internal open circuit. 2. Internal short. 3. Battery electrolyte leakage.
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5. Accumulation of sulphate crystals too big to be dispersed. These faults are normally caused by: 1. Component failure inside the element. 2. Excessive crystal growth leading to perforated separators and possibly short circuits. 3. Excessive overload (inefficient charging system, high voltage rapid charging, operation at high temperatures).
5. Crystals are formed when batteries are left flat. High temperatures and long periods in this condition accentuate the problem. If a battery is left at ambient temperature for a week, it will be difficult to recharge on the tractor. Recharging will require a higher constant voltage. After 3 weeks, the battery will be permanently damaged and it will be necessary to follow the procedure described for “extremely flat batteries”. Fully charged batteries last for longer. A lead−calcium battery discharges 3% every month. This means that in 16 months the charge will drop by 50%. The inactive load on the tractor is approx. 50mA. An approximate discharge on an unused vehicle is valued at 8Ah per week. It is worth noting that if a battery is weak during engine start−up, it is best to let the battery rest for two minutes. This rest time should increase as the temperature decreases. When two batteries are installed, do not use an old battery with a new one. One battery will always stop before the other. If the battery has lasted as forecasted, charge both batteries. If a battery stops before the prescribed time, due to a manufacturing fault, then only replace one of the batteries.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
1
SECTION 55 − ELECTRICAL SYSTEM
Chapter 5 − Electrical circuits CONTENTS Section
Description
Page
Electrical circuit components − numerical order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical circuit components − functional order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Location of fuses and relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Symbols used in electrical circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electric wire colour code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Wiring diagrams and connections identification code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Standard version (ISO − North America) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Electrical circuits index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Index to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Power Shuttle version (ISO − NORTH AMERICA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Electrical circuits index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Index to wiring harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
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2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 ELECTRICAL CIRCUIT COMPONENTS − Numerical order
2
Instrument
3
Starter switch.
4
4WD relay.
5
4WD relay.
6
Trailer brake relay (A−B−C)
9
Engine connection (24 PIN)
12
Trailer brake connection (6 PIN).
14
Fuse 30/40 A.
15
RH headlight connection.
16
LH headlight connection.
17
Brake lights switch.
18
Brake lights switch.
20
Starter relay.
21
Instrument panel ground.
22
Hazard lights switch.
23
4WD switch.
24
Swivel position lights switch.
25
Direction indicator lights switch.
26
Lights switch.
27
Electronic flasher.
28
Fusebox.
29
LH swivel position light.
30
Front LH light.
31
Front RH light.
32
RH swivel position light.
33
Battery.
34
Horn.
35
Air filter clogged switch.
36
Starter motor.
37
Engine stop electromagnet.
38
Brake fluid level switch.
39
Engine coolant temperature sensor.
40
Engine oil pressure switch.
41
Alternator.
42
Power steering indicator light pressure switch
43
Trailer brake indicator pressure switch.
44
Electrohydraulic 4WD indicator pressure switch.
45
4 WD indicator control connection.
46
4WD solenoid valve.
47
Mechanical 4WD indicator switch.
48
Gear switch connection.
49
Neutral gear switch.
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
3
ELECTRICAL CIRCUIT COMPONENTS − Numerical order (Continued) 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 67 68 69 70 71 72 73 74 75 76 77 78 79 81 83 84 85 86 87 88 89 90 91 92 93 94 95 98 99 100
Splitter switch. PTO indicator switch. Parking brake switch. Fuel gauge switch. RH tail light. 8A power socket. 7−pole connection. Work light. Number plate light. LH tail light. Rear ground. Trailer brake solenoid valves. Trailer brake safety pressure switch. LH two−faced headlight. RH two−faced headlight. Seat switch. Brake lights relay. Transmission connection. Transmission connection. G1 gear switch. C1 gear switch. Transmission oil temperature sensor. Transmission oil pressure switch. HIGH clutch solenoid valve. LOW clutch solenoid valve. Speed sensor. Dump solenoid valve. Trailer brake connection (4 PIN). Front lights connection (6 PIN) Operator safety circuit buzzer timer. 4WD circuit connection. Connection for 7−pole connection. Power Shuttle control unit. Clutch pedal switch. Clutch pedal sensor. 30A power socket (ISO) Power Shuttle control unit troubleshooting connection. Power Shuttle control lever. Solenoid valve to cut out starting advance, depending on temperature. Starting advance thermometric cut−out switch. Left−hand front headlight (North America version). Right−hand front headlight (North America version). 4WD circuit connection (12 PIN). Inlet Grid Heater Grid heater relay Grid−heater control unit 87744428A − 11 − 2007
4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 ELECTRICAL CIRCUIT COMPONENTS − Numerical order (Continued)
101 102 103 104 105 106 107 108 109 110
Grid heater connection 125 A mega−fuse Diesel filter separator sensor ”Up/Down” control push−button ”Enter” control push−button Engine connection (1 PIN) 50 A mega−fuse Engine rpm sensor Connection for 30A / 40A socket 40A power socket (North America)
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
5
ELECTRICAL CIRCUIT COMPONENTS − Functional order CONTROL UNITS 27 Electronic flasher. 28 Fusebox. 81 Operator safety circuit buzzer timer 85 Power Shuttle control unit 100 Grid−heater control unit SENSORS 39 Engine coolant temperature sensor. 42 Power steering indicator light pressure switch 43 Trailer brake indicator pressure switch. 44 Electrohydraulic 4WD indicator pressure switch 53 Fuel gauge switch. 62 Trailer brake safety pressure switch. 72 Transmission oil temperature sensor 76 Speed sensor 87 Clutch pedal sensor 103 Diesel filter separator sensor 108 Engine rpm sensor CONNECTIONS 9 Engine connection (24 PIN) 12 Trailer brake connection (4 PIN) 15 RH light connection. 16 LH light connection. 45 4 WD indicator control connection. 48 Gear switch connection. 68 Transmission connection 69 Transmission connection 78 Trailer brake connection (4 PIN) 79 Front lights connection (6 PIN) 83 4WD circuit connection 84 Connection for 7−pole connection 89 Power Shuttle control unit troubleshooting connection 95 4WD circuit connection (12 PIN) 101 Grid heater connection 106 Engine connection (1 PIN) 109 Connection for 30A / 40A socket SOLENOID VALVES 37 Engine stop electromagnet. 46 Four−wheel drive solenoid valve. 61 Trailer brake solenoid valves. 74 HIGH clutch control solenoid valve 75 LOW clutch control solenoid valve 87744428A − 11 − 2007
6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 ELECTRICAL CIRCUIT COMPONENTS − Functional order (Continued)
77 91
Dump solenoid valve Solenoid valve to cut out starting advance, depending on temperature
HEADLIGHTS − LIGHTS 29 LH swivel position light 30 Front LH light. 31 Front RH light. 32 RH swivel position light 54 RH tail light 57 Work light. 58 Number plate light. 59 LH tail light. 63 LH two−faced headlight 64 RH two−faced headlight 93 Left−hand front headlight (North America version) 94 Right−hand front headlight (North America version) SWITCHES 3 Start switch. 17 Brake lights switch. 18 Brake lights switch. 22 Hazard lights switch. 23 4WD control switch. 24 Angular headlight switch. 25 Direction indicator control switch. 26 Lights switch. 35 Air filter clogged switch. 38 Brake fluid level switch. 40 Engine oil pressure switch. 47 Mechanical 4 WD indicator switch. 49 Neutral gear switch. 50 Splitter switch. 51 PTO indicator switch. 52 Parking brake switch. 65 Seat switch 70 G1 gear switch 71 C1 gear switch 73 Engine oil pressure switch 86 Clutch pedal switch 90 Power Shuttle control lever 92 Starting advance thermometric cut−out switch 104 ”Up/Down” control push−button 105 ”Enter” control push−button
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SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
7
ELECTRICAL CIRCUIT COMPONENTS − Functional order (Continued) POWER SOCKETS 55 8A power socket. 56 7−pole connection. 88 30A power socket (ISO) 110 40A power socket (North America) RELAYS 4 4WD relay. 5 4WD relay. 6 Trailer brake relay (A−B−C) 20 Starter relay. 67 Brake lights relay 99 Grid heater relay MAXI−FUSES 14 30/40 A fuse 102 125 A mega−fuse 107 50 A mega−fuse MISCELLANEOUS COMPONENTS 33 Battery. 34 Horn. 41 Alternator. 98 Inlet Grid Heater
87744428A − 11 − 2007
8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 LOCATION OF FUSES AND RELAYS
VERSION A (ISO−Power Shuttle unit) − Fig. 1 Models with electro−hydraulic four−wheel drive fitted for: −
Swivel position lights
−
8A and 25A power sockets
−
Italia trailer brake.
6
a
b
MPH1943A
1
RELAYS AND CONTROL UNITS − LH SIDE (a)
RELAYS AND CONTROL UNITS − RH SIDE (b)
1. 2. 3. 4. 5. 6.
1. Electronic flasher. 2. Starter relay. 3. 30 A Maxi−fuse.
4WD relay. 4WD relay. Brake lights relay. Trailer brake relay. Trailer brake relay. Trailer brake relay.
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
9
VFuses version A (model ISO−Power Shuttle) Valves
Amps.
1
5
Engine stop electromagnet.
2
10
Direction indicators circuit.
3
15
LH tail/side lights and tail/side lights indicator, pin 2 seven−pole connection.
4
5
RH tail/side lights and controls and instruments lighting.
5
15
Full beam headlights.
6
15
Dipped beam headlights.
15
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit.
8
15
Swivel position lights and work light.
9
5
Starter safety circuit.
10
10
Electrohydraulic 4WD circuit.
11
15
Hazard lights and full beam flasher circuit.
12
15
Horn, 8A power socket, buzzer.
13
10
Brake lights circuit.
14
10
Power Shuttle circuit (+ key).
15
5
Power shuttle lever circuit.
16
5
Power Shuttle circuit (+ battery), buzzer, instrument.
30
ISO power socket Maxi−fuse.
7
PROTECTED CIRCUITS
Maxi−fuse 17
Colour of fuses Colour
Amps.
Beige
5
Red
10
Blue
15
Green
30
Orange
40
CAUTION 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 fuses − even if interchangeable − could seriously affect tractor control with dangerous results.
87744428A − 11 − 2007
10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
VERSION B (ISO standard) − Fig. 2 Models with mechanical four−wheel drive (ISO) fitted for: − − −
Swivel position lights 8A and 25A power sockets Italia trailer brake.
a
b
MPH1944A
2
RELAYS AND CONTROL UNITS − LH SIDE (a) 1. Brake lights relay.
RELAYS AND CONTROL UNITS − RH SIDE (b) 1. Electronic flasher.
2. Trailer brake relay. 3. Trailer brake relay. 4. Trailer brake relay. 87744428A − 11 − 2007
2. Starter relay. 3. 30 A Maxi−fuse.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
11
VFuses version B (model ISO standard) Fuses
Amps.
1
5
Engine stop electromagnet.
2
10
Direction indicators circuit.
3
15
LH tail/side lights, pin 2 seven−pole connection.
4
5
RH tail/side lights and controls and instruments lighting.
5
15
Full beam headlights.
6
15
Dipped beam headlights.
15
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit.
8
15
Swivel position lights and work light.
9
5
Starter safety circuit.
10
10
Electrohydraulic 4WD circuit.
11
15
Hazard lights and full beam flasher circuit.
12
15
Horn, 8A power socket.
13
10
Brake lights circuit.
14
−
Not used.
15
−
Not used.
16
5
Instrument.
30
ISO power socket Maxi−fuse.
7
PROTECTED CIRCUITS
Maxi−fuse 17
Fuse colours Colour
Amps.
Beige
5
Red
10
Blue
15
Green
30
Orange
40
CAUTION 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 fuses − even if interchangeable − could seriously affect tractor control with dangerous results.
87744428A − 11 − 2007
12
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
VERSION C (NORTH AMERICA−Power Shuttle) − Fig. 3 Models with mechanical transmission fitted for: − − −
Swivel position lights 8A and 40A power sockets Electrohydraulic 4WD.
a
2
3
4
b
MPH1945A
3
RELAYS AND CONTROL UNITS − LH SIDE (a) 1. Brake lights relay.
RELAYS AND CONTROL UNITS − RH SIDE (b) 1. 4WD relay. 2. 4WD relay.
2. Alarm module. 3. Electronic flasher. 87744428A − 11 − 2007
3. Starter relay. 4. 40 A Maxi−fuse.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
13
VFuses version C (model NORTH AMERICA−Power Shuttle)
Valves
Amps.
1
5
Engine stop electromagnet.
2
5
Grid−heater control unit circuit.
3
15
LH tail/side lights and tail/side lights indicator, 7−pole connection.
4
5
RH tail/side lights and controls and instruments lighting.
5
15
Full beam headlights.
6
15
Dipped beam headlights.
10
Power take−off safety circuit North America, + instrument common, diesel filter separator.
8
15
Swivel position lights and rear work light.
9
5
Starter safety circuit.
10
10
4WD circuit.
11
25
Direction indicator lights, hazard lights, flasher full beam circuit.
12
10
8A power socket, buzzer.
13
10
Brake lights circuit.
14
10
Power shuttle circuit (+key).
15
5
Power shuttle lever circuit.
16
5
Power Shuttle control unit power supply (+battery), Instrument.
40
North America power socket maxi−fuse.
7
PROTECTED CIRCUITS
Maxi−fuse 17
Colour of fuses
Colour
Amps.
Beige
5
Red
10
Blue
15
Green
30
Orange
40
CAUTION 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 fuses − even if interchangeable − could seriously affect tractor control with dangerous results.
87744428A − 11 − 2007
14
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
VERSION D (NORTH AMERICA standard) − Fig. 4 Models with mechanical transmission fitted for: − − −
Swivel position lights 8A and 40A power sockets Electrohydraulic 4WD.
a
2
3
4
b
MP1946A
4
RELAYS AND CONTROL UNITS − LH SIDE (a) 1. Brake lights relay.
RELAYS AND CONTROL UNITS − RH SIDE (b) 1. 4WD relay. 2. 4WD relay.
2. Alarm module. 3. Electronic flasher. 87744428A − 11 − 2007
3. Starter relay. 4. 40 A Maxi−fuse.
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
15
VFuses version D (model NORTH AMERICA standard)
Fuses
Amps.
1
5
Engine stop electromagnet.
2
5
Grid−heater control unit circuit.
3
15
LH tail/side lights and tail/side lights indicator, 7−pole connection.
4
5
RH tail/side lights and controls and instruments lighting.
5
15
Full beam headlights.
6
15
Dipped beam headlights.
10
Power take−off safety circuit North America, + instrument common, diesel filter separator.
8
15
Swivel position lights and rear work light.
9
5
Starter safety circuit.Starter safety circuit.
10
10
Electrohydraulic 4WD circuit.
11
25
Direction indicator lights, hazard lights, flasher full beam circuit.
12
10
8A power socket, buzzer.
13
10
Brake lights circuit.
14
−
Not used.
15
−
Not used.
16
5
Instrument (+battery).
40
North America power socket maxi−fuse.
7
PROTECTED CIRCUITS
Maxi−fuse 17
Fuse colours
Colour
Amps.
Beige
5
Red
10
Blue
15
Green
30
Orange
40
CAUTION 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 fuses − even if interchangeable − could seriously affect tractor control with dangerous results.
87744428A − 11 − 2007
16
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SYMBOLS USED IN ELECTRICAL CIRCUITS
Speaker Starter switch Diode
Battery
Connection
Connection Fuse
Motor
Thermostarter
Lights and warning indicators
Horn
Switch relay
Switch relay
Pressure switch/Sensor
Indicator switch
MPD2703A
87744428A − 11 − 2007
Variable resistor
Cigar lighter
Power socket
Control switch
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
17
SYMBOLS USED IN ELECTRICAL CIRCUITS (continued)
Switch
Solenoid valve
Inductive sensor
Solenoid valve
Sensor
Flasher
MPD2704A
87744428A − 11 − 2007
18
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 WIRE COLOUR CODING
A
Light Blue
HV
Grey/green
AN
Light blue/black
HG
Grey/yellow
AG
Light blue/yellow
L
Blue
AB
Light blue/white
LB
Blue/white
AV
Light blue/green
LN
Blue/black
AR
Light blue/red
LR
Blue/red
B
White
M
Brown
BR
White/red
MB
Brown/white
BN
White/black
MN
Brown/black
BL
White/blue
N
Black
BG
White/yellow
NZ
Black/purple
C
Orange
NB
Black/white
CB
Orange/white
NR
Black/red
CN
Orange/black
R
Red
CL
Orange/blue
RG
Red/yellow
G
Yellow
RN
Red/black
GV
Yellow/green
RV
Red/green
GN
Yellow/black
S
Pink
GR
Yellow/red
SN
Pink/black
GL
Yellow/blue
SG
Pink/yellow
H
Grey
V
Green
HM
Grey/brown
VN
Green/black
HR
Grey/red
VB
Green/white
HN
Grey/black
Z
Purple
HB
Grey/white
ZB
Purple/white
HL
Blue/Grey
ZN
Purple/black
WIRING DIAGRAMS AND CONNECTIONS IDENTIFICATION CODE
0.5 −
WIRE SECTION WIRE COLOUR No. PIN ON CONNECTION (where relevant)
87744428A − 11 − 2007
RN −
(3)
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
19
STANDARD VERSION (ISO−NORTH AMERICA)
ELECTRICAL CIRCUITS INDEX
DESCRIPTION
DIAGRAM
PAGE
Front part circuit
A
22
Power sockets and operator safety circuit (North America version)
B
24
Transmission circuit (North America version)
C
28
Front lights circuit
D/1
32
Front lights circuit
D/2
34
Lighting circuit (ISO version)
E
38
Lights circuit (North America version)
F
42
Trailer brake circuit (ISO version)
G
46
Mechanical and electrohydraulic four−wheel drive circuit
H
48
Transmission circuit (ISO version)
I
52
Transmission circuit (ISO version)
L
54
Transmission circuit (North America version)
M
58
Sensors, transmitters and instrument circuit
N
62
INDEX TO WIRING HARNESSES
DESCRIPTION
PAGE
Wiring diagrams A−B
21
Wiring diagram C
27
Wiring diagrams D/1 − D/2
31
Wiring diagram E
37
Wiring diagram F
41
Wiring diagrams G−H
45
Wiring diagrams I−L
51
Wiring diagram M
57
Wiring diagram N
61
87744428A − 11 − 2007
20
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
OPERATOR SAFETY CIRCUIT − Fig. 5 DESCRIPTION The circuit is composed of an alarm module with acoustic warning device (2) connected to the handbrake switch, a sensor located under the driving seat and the rear PTO switch. The alarm module is positioned inside the dashboard, on the LH side, between the brake lights relay (1) and the light flasher module (3).
MPD2803A
5
OPERATION The circuit can operate in three ways: 1. With the engine running and no one seated in the driving position, with the handbrake disengaged and the PTO ON, the alarm is activated. 2. With the engine running and the driving position occupied, the alarm is always deactivated. 3. With the engine running and with the driving position occupied/free, with the handbrake disengaged and the PTO ON or OFF, the alarm is activated.
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
21
WIRING DIAGRAMS A−B
MPM1107A
6 87744428A − 11 − 2007
22
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 CIRCUITO PARTE ANTERIORE (Schema A)
2
Strumento
3
Commutatore d’avviamento
9
Connessione motore (24 PIN)
20
Relais avviamento
28
Scatola fusibili F1
Elettromagnete d’arresto motore
F2
Circuito luci di direzione
F9
Circuito sicurezza avviamento
33
Batteria
36
Motorino d’avviamento
37
Elettromagnete d’arresto motore
41
Alternatore
69
Connessione trasmissione
91
Elettrovalvola esclusione anticipo all’avviamento, in funzione della temperatura
92
Interruttore termometrico esclusione anticipo all’avviamento
98
Grid heater
99
Relais grid heater
100 Centralina grid heater 101 Connessione per grid heater 102 Megafusibile 125 A 106 Connessione motore (1 PIN) 107 Megafusibile 50 A
D
F2 = 10 A (ISO) F2 = 5 A (Nord America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
23
FRONT PART CIRCUIT − DIAGRAM A
MPM1073A
87744428A − 11 − 2007
24
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 POWER SOCKETS AND OPERATOR SAFETY CIRCUIT (North America version) (Diagram B)
14
30/40 A fuse
28
Fusebox F7
Power take−off safety circuit North America, + instrument common, diesel filter separator
F12 8A power socket, buzzer 69
Transmission connection
81
Operator safety circuit buzzer timer
88
30A power socket (ISO)
106 Engine connection (1 PIN) 107 50 A mega−fuse 109 Connection for 30A / 40A socket 110 40A power socket (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
25
POWER SOCKETS AND OPERATOR SAFETY CIRCUIT (North America version) − DIAGRAM B
MPM1074A
87744428A − 11 − 2007
26
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
27
WIRING DIAGRAM C
MPM1108A
7 87744428A − 11 − 2007
28
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (North America version) (Diagram C)
2
Instrument
9
Engine connection (24 PIN)
20
Starter relay
27
Electronic flasher
28
Fusebox F3
LH tail/side lights and tail/side lights indicator, 7−pole connection
F4
RH tail/side lights and controls and instruments lighting
F7
Power take−off safety circuit North America, + instrument common, diesel filter separator
F8
Swivel position lights and rear work light
F9
Starter safety circuit
F11
Direction indicator lights, hazard lights, flasher full beam circuit
F12
8A power socket, buzzer
F16
Instrument (+battery)
69
Transmission connection
81
Operator safety circuit buzzer timer
95
4WD circuit connection (12 PIN)
D
See diagram M − Page 59
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
29
TRANSMISSION CIRCUIT (North America version) − DIAGRAM C
MPM1075A
87744428A − 11 − 2007
30
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
31
WIRING DIAGRAMS D/1−D/2
MPM1109A
8 87744428A − 11 − 2007
32
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 FRONT LIGHTS CIRCUIT (Diagram D/1)
29
LH swivel position light
30
Front LH light
31
Front RH light
32
RH swivel position light
34
Horn
79
Front lights connection (6 PIN)
93
Left−hand front headlight (North America version)
94
Right−hand front headlight (North America version)
Y
See diagram D/2 − Page 35
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
33
FRONT LIGHTS CIRCUIT − DIAGRAM D/1
MPM1076A
87744428A − 11 − 2007
34
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 FRONT LIGHTS CIRCUIT (Diagram D/2)
2
Instrument
15
RH light connection
16
LH light connection
22
Hazard lights switch
24
Angular headlight switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F2
Direction indicators circuit
F3
LH tail/side lights, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F5
Full beam headlights
F6
Dipped beam headlights
F8
Swivel position lights and work light
F11
Hazard lights and full beam flasher circuit
F12
Horn, 8A power socket
57
Work light
79
Front lights connection (6 PIN)
69
Transmission connection
Y
See diagram D/1 − Page 33
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
35
FRONT LIGHTS CIRCUIT − DIAGRAM D/2
MPM1077A
87744428A − 11 − 2007
36
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
37
WIRING DIAGRAM E
MPM1110A
9 87744428A − 11 − 2007
38
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 LIGHTS CIRCUIT (ISO version) (Diagram E)
2
Instrument
15
RH light connection
16
LH light connection
22
Hazard lights switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F2
Direction indicators circuit
F3
LH tail/side lights, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F11 Hazard lights and full beam flasher circuit 54
RH tail light
58
Number plate light
59
LH tail light
69
Transmission connection
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
39
LIGHTS CIRCUIT (ISO version) − DIAGRAM E
MPM1078A
87744428A − 11 − 2007
40
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
41
WIRING DIAGRAM F
MPM1111A
10 87744428A − 11 − 2007
42
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 LIGHTS CIRCUIT (North America version) (Diagram F)
2
Instrument
22
Hazard lights switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F3
LH tail/side lights and tail/side lights indicator, 7−pole connection
F4
RH tail/side lights and controls and instruments lighting
F7
Power take−off safety circuit North America, + instrument common, diesel filter separator
F11
Direction indicator lights, hazard lights, flasher full beam circuit
56
7−pole connection
63
LH two−faced headlight
64
RH two−faced headlight
69
Transmission connection
84
Connection for 7−pole connection
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
43
LIGHTS CIRCUIT (North America version) − DIAGRAM F
MPM1079A
87744428A − 11 − 2007
44
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
45
WIRING DIAGRAMS G−H
MPM1112A
11 87744428A − 11 − 2007
46
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRAILER BRAKE (ISO version) (Diagram G)
2
Instrument
6
Trailer brake relay (A−B−C)
12
Trailer brake connection (4 PIN)
28
Fusebox F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F16
Instrument
43
Trailer brake indicator pressure switch
52
Parking brake switch
61
Trailer brake solenoid valves
62
Trailer brake safety pressure switch
69
Transmission connection
78
Trailer brake connection (4 PIN)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
47
TRAILER BRAKE (ISO version) − DIAGRAM G
MPM1080A
87744428A − 11 − 2007
48
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 MECHANICAL AND ELECTROHYDRAULIC FOUR−WHEEL DRIVE (Diagram H)
2
Instrument
4
4WD relay
5
4WD relay
17
Brake lights switch
18
Brake lights switch
23
4WD control switch
28
Fusebox F10
Electrohydraulic 4WD circuit
F13
Brake lights circuit
44
Electrohydraulic 4WD indicator pressure switch
46
Four−wheel drive solenoid valve
47
Mechanical 4 WD indicator switch
67
Brake lights relay
69
Transmission connection
83
4WD circuit connection
95
4WD circuit connection (12 PIN)
D Electrohydraulic 4WD version DD Mechanical 4WD version DDD Jumper for version with mechanical four−wheel drive
*
North America version
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
49
MECHANICAL AND ELECTROHYDRAULIC FOUR−WHEEL DRIVE − DIAGRAM H
MPM1081A
87744428A − 11 − 2007
50
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
51
WIRING DIAGRAMS I−L
MPM1113A
12 87744428A − 11 − 2007
52
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (ISO version) (Diagram I)
48
Gear switch connection
49
Neutral gear switch
50
Splitter switch
51
PTO indicator switch
52
Parking brake switch
53
Fuel gauge switch
54
RH tail light
55
8A power socket
56
7−pole connection
57
Work light
58
Number plate light
59
LH tail light
69
Transmission connection
D Standard version DD Splitter version DDD See diagram L − Page 55
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
53
TRANSMISSION CIRCUIT (ISO version) − DIAGRAM I
MPM1082A
87744428A − 11 − 2007
54
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (ISO version) (Diagram L)
2
Instrument
9
Engine connection (24 PIN)
12
Trailer brake connection (4 PIN)
20
Starter relay
28
Fusebox F3
LH tail/side lights, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F8
Swivel position lights and work light
F9
Starter safety circuit
F12
Horn, 8A power socket
F16
Instrument
69
Transmission connection
83
4WD circuit connection
DDD See diagram I − Page 53
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
55
TRANSMISSION CIRCUIT (ISO version) − DIAGRAM L
MPM1083A
87744428A − 11 − 2007
56
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
57
WIRING DIAGRAM M
MPM1114A
13 87744428A − 11 − 2007
58
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (North America version) (Diagram M)
Mechanical 4 WD indicator switch
49
Neutral gear switch
52
Parking brake switch
53
Fuel gauge switch
55
8A power socket
56
7−pole connection
57
Work light
63
LH two−faced headlight
64
RH two−faced headlight
65
Seat switch
69
Transmission connection
84
Connection for 7−pole connection
D
47
See diagram C − Page 29
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
59
TRANSMISSION CIRCUIT (North America version) − Diagram M
MPM1084A
87744428A − 11 − 2007
60
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
61
WIRING DIAGRAM N
MPM1115A
14 87744428A − 11 − 2007
62
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 SENSORS, TRANSMITTERS AND INSTRUMENT CIRCUIT (Diagram N)
2
Instrument
9
Engine connection (24 PIN)
28
Fusebox F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F16
Instrument
35
Air filter clogged switch
38
Brake fluid level switch
39
Engine coolant temperature sensor
40
Engine oil pressure switch
42
Power steering indicator light pressure switch
53
Fuel gauge switch
69
Transmission connection
103 Diesel filter separator sensor 108 Engine rpm sensor
D
F7 = 7.5 A (ISO) F7 = 10 A (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
63
SENSORS, TRANSMITTERS AND INSTRUMENT CIRCUIT − DIAGRAM N
MPM1085A
87744428A − 11 − 2007
64
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
65
POWER SHUTTLE VERSION (ISO−NORTH AMERICA)
INDEX TO ELECTRICAL CIRCUIT DESCRIPTION
DIAGRAM
PAGE
A
68
Front lights circuit
B/1
72
Front lights circuit
B/2
74
Lighting circuit (ISO version)
C
78
Lights circuit (North America version)
D
82
Trailer brake circuit (ISO version)
E
86
Mechanical and electrohydraulic four−wheel drive circuit
F
88
Transmission circuit (ISO version)
G
92
Transmission circuit (ISO version)
H
94
Transmission circuit (Power Shuttle control unit)
I
98
Transmission circuit (North America version)
L
100
Transmission circuit (North America version)
M
102
Sensors, transmitters and instrument circuit
N
106
Front part circuit
INDEX TO WIRING HARNESSES DESCRIPTION
No. PAGE
Wiring diagram A
67
Wiring diagrams B/1 − B/2
71
Wiring diagram C
77
Wiring diagram D
81
Wiring diagram E−F
85
Wiring diagrams G−H
91
Wiring diagrams I − L − M
97
Wiring diagram N
105
87744428A − 11 − 2007
66
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
67
WIRING DIAGRAM A
MPM1116A
15 87744428A − 11 − 2007
68
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 FRONT PART CIRCUIT (Diagram A)
2
Instrument
3
Start switch
9
Engine connection (24 PIN)
20
Starter relay
28
Fusebox F1
Engine stop electromagnet
F2
Direction indicators circuit
F9
Starter safety circuit
33
Battery
36
Starter motor
37
Engine stop electromagnet
41
Alternator
86
Clutch pedal switch
90
Power Shuttle control lever
91
Solenoid valve to cut out starting advance, depending on temperature
92
Starting advance thermometric cut−out switch
98
Inlet Grid Heater
99
Grid heater relay
100 Grid−heater control unit 101 Grid heater connection 102 125 A mega−fuse 106 Engine connection (1 PIN) 107 50 A mega−fuse
D
F2 = 10 A (ISO) F2 = 5 A (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
69
FRONT PART CIRCUIT − DIAGRAM A
MPM1094A
87744428A − 11 − 2007
70
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
71
WIRING DIAGRAMS B/1−B/2
MPM1117A
16 87744428A − 11 − 2007
72
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 FRONT LIGHTS CIRCUIT (Diagram B/1)
29
LH swivel position light
30
Front LH light
31
Front RH light
32
RH swivel position light
34
Horn
79
Front lights connection (6 PIN)
93
Left−hand front headlight (North America version)
94
Right−hand front headlight (North America version)
Y
See diagram B/2 − Page 75
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
73
FRONT LIGHTS CIRCUIT − DIAGRAM B/1
MPM1095A
87744428A − 11 − 2007
74
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 FRONT LIGHTS CIRCUIT (Diagram B/2)
2
Instrument
15
RH light connection
16
LH light connection
22
Hazard lights switch
24
Angular headlight switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F2
Direction indicators circuit
F3
LH tail/side lights and tail/side lights indicator, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F5
Full beam headlights
F6
Dipped beam headlights
F8
Swivel position lights and work light
F11
Hazard lights and full beam flasher circuit
F12
Horn, 8A power socket, buzzer
57
Work light
69
Transmission connection
79
Front lights connection (6 PIN)
Y
See diagram B/1 − Page 73
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
75
FRONT LIGHTS CIRCUIT − DIAGRAM B/2
MPM1096A
87744428A − 11 − 2007
76
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
77
WIRING DIAGRAM C
MPM1118A
17 87744428A − 11 − 2007
78
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 LIGHTS CIRCUIT (ISO version) (Diagram C)
2
Instrument
15
RH light connection
16
LH light connection
22
Hazard lights switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F2
Direction indicators circuit
F3
LH tail/side lights and tail/side lights indicator, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F11
Hazard lights and full beam flasher circuit
54
RH tail light
58
Number plate light
59
LH tail light
69
Transmission connection
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
79
LIGHTS CIRCUIT (ISO version) − DIAGRAM C
MPM1097A
87744428A − 11 − 2007
80
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
81
WIRING DIAGRAM D
MPM1119A
18 87744428A − 11 − 2007
82
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 LIGHTS CIRCUIT (North America version) (Diagram D)
2
Instrument
22
Hazard lights switch
25
Direction indicator control switch
26
Lights switch
27
Electronic flasher
28
Fusebox F3
LH tail/side lights and tail/side lights indicator, 7−pole connection
F4
RH tail/side lights and controls and instruments lighting
F7
Power take−off safety circuit North America, + instrument common, diesel filter separator
F11
Direction indicator lights, hazard lights, flasher full beam circuit
56
7−pole connection
63
LH two−faced headlight
64
RH two−faced headlight
69
Transmission connection
84
Connection for 7−pole connection
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
83
LIGHTS CIRCUIT (North America version) − DIAGRAM D
MPM1098A
87744428A − 11 − 2007
84
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
85
WIRING DIAGRAMS E−F
MPM1120A
19 87744428A − 11 − 2007
86
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRAILER BRAKE (ISO version) (Diagram E)
2
Instrument
6
Trailer brake relay (A−B−C)
12
Trailer brake connection (4 PIN)
28
Fusebox F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F16
Power Shuttle circuit (+ battery), buzzer, instrument
43
Trailer brake indicator pressure switch
52
Parking brake switch
61
Trailer brake solenoid valves
62
Trailer brake safety pressure switch
69
Transmission connection
78
Trailer brake connection (4 PIN)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
87
TRAILER BRAKE (ISO version) − DIAGRAM E
MPM1099A
87744428A − 11 − 2007
88
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 MECHANICAL AND ELECTROHYDRAULIC FOUR−WHEEL DRIVE (Diagram F)
2
Instrument
4
4WD relay
5
4WD relay
17
Brake lights switch
18
Brake lights switch
23
4WD control switch
28
Fusebox F10
Electrohydraulic 4WD circuit
F13
Brake lights circuit
44
Electrohydraulic 4WD indicator pressure switch
46
Four−wheel drive solenoid valve
47
Mechanical 4 WD indicator switch
67
Brake lights relay
69
Transmission connection
83
4WD circuit connection
95
4WD circuit connection (12 PIN)
D Electrohydraulic 4WD version DD Mechanical 4WD version DDD Jumper for version with mechanical four−wheel drive
*
North America version
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
89
MECHANICAL AND ELECTROHYDRAULIC FOUR−WHEEL DRIVE − DIAGRAM F
MPM1100A
87744428A − 11 − 2007
90
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
91
WIRING DIAGRAMS G−H
MPM1121A
20 87744428A − 11 − 2007
92
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (ISO version) (Diagram G)
51
PTO indicator switch
52
Parking brake switch
53
Fuel gauge switch
54
RH tail light
55
8A power socket
56
7−pole connection
57
Work light
58
Number plate light
59
LH tail light
65
Seat switch
69
Transmission connection
76
Speed sensor
Y
See diagram H − Page 95
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
93
TRANSMISSION CIRCUIT (ISO version) − DIAGRAM G
MPM1101A
87744428A − 11 − 2007
94
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (ISO version) (Diagram H)
2
Instrument
9
Engine connection (24 PIN)
28
Fusebox F3
LH tail/side lights and tail/side lights indicator, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F12
Horn, 8A power socket, buzzer
F16
Power Shuttle circuit (+ battery), buzzer, instrument
69
Transmission connection
83
4WD circuit connection
Y
See diagram G − Page 93
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
95
TRANSMISSION CIRCUIT (ISO version) − DIAGRAM H
MPM1102A
87744428A − 11 − 2007
96
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
97
WIRING DIAGRAMS I − L − M
MPM1122A
21 87744428A − 11 − 2007
98
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (Power Shuttle control unit) (Diagram I)
2
Instrument
28
Fusebox F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F14
Power Shuttle circuit (+ key)
F15
Power shuttle lever circuit
F16
Power Shuttle circuit (+ battery), buzzer, instrument
68
Transmission connection
70
G1 gear switch
71
C1 gear switch
72
Transmission oil temperature sensor
73
Engine oil pressure switch
74
HIGH clutch control solenoid valve
75
LOW clutch control solenoid valve
77
Dump solenoid valve
85
Power Shuttle control unit
86
Clutch pedal switch
87
Clutch pedal sensor
89
Connection for Power Shuttle control unit troubleshooting
90
Power Shuttle control lever
D Y
F7 = 15 A (ISO) F7 = 10 A (North America) See diagram M − Page 103
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
99
TRANSMISSION CIRCUIT (Power Shuttle control unit) − DIAGRAM I
MPM1103A
87744428A − 11 − 2007
100
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (North America version) (Diagram L)
2
Instrument
9
Engine connection (24 PIN)
27
Electronic flasher
28
Fusebox F3
LH tail/side lights and tail/side lights indicator, pin 2 seven−pole connection
F4
RH tail/side lights and controls and instruments lighting
F8
Swivel position lights and work light
F11
Hazard lights and full beam flasher circuit
F12
Horn, 8A power socket, buzzer
69
Transmission connection
83
4WD circuit connection
YY See diagram M − Page 103
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
101
TRANSMISSION CIRCUIT (North America version) − DIAGRAM L
MPM1104A
87744428A − 11 − 2007
102
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 TRANSMISSION CIRCUIT (North America version) (Diagram M)
51
PTO indicator switch
52
Parking brake switch
53
Fuel gauge switch
55
8A power socket
56
7−pole connection
57
Work light
63
LH two−faced headlight
64
RH two−faced headlight
65
Seat switch
68
Transmission connection
69
Transmission connection
70
G1 gear switch
71
C1 gear switch
72
Transmission oil temperature sensor
73
Engine oil pressure switch
74
HIGH clutch control solenoid valve
75
LOW clutch control solenoid valve
76
Speed sensor
77
Dump solenoid valve
84
Connection for 7−pole connection
Y
See diagram I − Page 99
YY See diagram L − Page 101
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
103
TRANSMISSION CIRCUIT (North America version) − DIAGRAM M
MPM1105A
87744428A − 11 − 2007
104
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
105
WIRING DIAGRAM N
MPM1123A
22 87744428A − 11 − 2007
106
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5 SENSORS, TRANSMITTERS AND INSTRUMENT CIRCUIT (Diagram N)
2
Instrument
9
Engine connection (24 PIN)
14
30/40 A fuse
28
Fusebox F7
Power take−off safety circuit, + instrument common, diesel filter separator, grid heater control unit circuit
F16
Power Shuttle circuit (+ battery), buzzer, instrument
35
Air filter clogged switch
38
Brake fluid level switch
39
Engine coolant temperature sensor
40
Engine oil pressure switch
42
Power steering indicator light pressure switch
53
Fuel gauge switch
69
Transmission connection
88
Power socket 30A (ISO)
103 Diesel filter separator sensor 104 ”Up/Down” control push−button 105 ”Enter” control push−button 106 Connection engine (1 PIN) 107 50 A mega−fuse 108 Engine rpm sensor 109 Connection for 30A / 40A socket 110 40A power socket (North America)
D
F7 = 15 A (ISO) F7 = 10 A (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
107
SENSORS, TRANSMITTERS AND INSTRUMENT CIRCUIT − DIAGRAM N
MPM1106A
87744428A − 11 − 2007
108
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 5
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
1
SECTION 55 − ELECTRICAL SYSTEM
Chapter 6 − Connectors INDICE Section
Description
Page
Electrical circuit components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 List of connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
87744428A − 11 − 2007
2
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6 ELECTRICAL CIRCUIT COMPONENTS
2 3 4 5 6 9 12 14 15 16 17 18 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49
Instrument Start switch. 4WD relay. 4WD relay. Trailer brake relay (A−B−C) Engine connection (24 PIN) Trailer brake connection (4 PIN) 30/40 A fuse RH light connection. LH light connection. Brake lights switch. Brake lights switch. Starter relay. Control panel ground Hazard lights switch. 4WD control switch. Angular headlight switch. Direction indicator control switch. Lights switch. Electronic flasher. Fusebox. LH swivel position light Front LH light. Front RH light. RH swivel position light Battery. Horn. Air filter clogged switch. Starter motor. Engine stop electromagnet. Brake fluid level switch. Engine coolant temperature sensor. Engine oil pressure switch. Alternator. Power steering indicator light pressure switch Trailer brake indicator pressure switch. Electrohydraulic 4WD indicator pressure switch 4 WD indicator control connection. Four−wheel drive solenoid valve. Mechanical 4 WD indicator switch. Gear switch connection. Neutral gear switch.
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
3
ELECTRICAL CIRCUIT COMPONENTS (Continued) 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 67 68 69 70 71 72 73 74 75 76 77 78 79 81 83 84 85 86 87 88 89 90 91 92 93 94 95 98 99 100
Splitter switch. PTO indicator switch. Parking brake switch. Fuel gauge switch. RH tail light 8A power socket. 7−pole connection. Work light. Number plate light. LH tail light. Rear ground Trailer brake solenoid valves. Trailer brake safety pressure switch. LH two−faced headlight RH two−faced headlight Seat switch Brake lights relay Transmission connection Transmission connection G1 gear switch C1 gear switch Transmission oil temperature sensor Engine oil pressure switch HIGH clutch control solenoid valve LOW clutch control solenoid valve Speed sensor Dump solenoid valve Trailer brake connection (4 PIN) Front lights connection (6 PIN) Operator safety circuit buzzer timer 4WD circuit connection Connection for 7−pole connection Power Shuttle control unit Clutch pedal switch Clutch pedal sensor 30A power socket (ISO) Power Shuttle control unit troubleshooting connection Power Shuttle control lever Solenoid valve to cut out starting advance, depending on temperature Starting advance thermometric cut−out switch Left−hand front headlight (North America version) Right−hand front headlight (North America version) 4WD circuit connection (12 PIN) Inlet Grid Heater Grid heater relay Grid−heater control unit 87744428A − 11 − 2007
4
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6 ELECTRICAL CIRCUIT COMPONENTS (Continued)
101 102 103 104 105 106 107 108 109 110
Grid heater connection 125 A mega−fuse Diesel filter separator sensor ”Up/Down” control push−button ”Enter” control push−button Engine connection (1 PIN) 50 A mega−fuse Engine rpm sensor Connection for 30A / 40A socket 40A power socket (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
5
LIST OF CONNECTORS
87744428A − 11 − 2007
6
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
1 Standard version (ISO)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
7
2 Version with Power Shuttle (ISO)
87744428A − 11 − 2007
8
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
3 Standard version (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
9
4 Version with Power Shuttle (North America)
87744428A − 11 − 2007
10
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
5
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
11
6 For ISO version only
87744428A − 11 − 2007
12
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
7
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
13
8
87744428A − 11 − 2007
14
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
9
*
Standard version (ISO)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
15
D
*
Y
10
D
Version with Power Shuttle (ISO)
*
Standard version (North America)
Y
Version with Power Shuttle (North America)
87744428A − 11 − 2007
16
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
**
11
* **
ISO version North America version
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
17
*
**
12
* **
ISO version North America version
87744428A − 11 − 2007
18
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
**
13
* **
ISO version North America version
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
19
*
**
14
* **
ISO version Standard version (North America)
87744428A − 11 − 2007
20
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
15
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
21
16
87744428A − 11 − 2007
22
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
17
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
23
18
87744428A − 11 − 2007
24
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
19
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
25
*
*
20
*
Only for standard version (ISO − North America)
87744428A − 11 − 2007
26
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
D
Y
21
*
Only for standard version (ISO − North America)
D
Version with Power Shuttle (ISO − North America)
Y
Standard version (ISO − North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
27
*
**
22
* **
ISO standard version and with Power Shuttle Standard version (North America)
87744428A − 11 − 2007
28
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
23
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
29
24
87744428A − 11 − 2007
30
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
D
Y
25
*
Standard version (ISO)
D
Version with Power Shuttle (ISO)
Y
North America version
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
31
*
*
26
*
Only for North America version
87744428A − 11 − 2007
32
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
**
27
* **
Standard version (North America) Version with Power Shuttle (ISO − North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
33
*
**
28
* **
Version with Power Shuttle (ISO − North America) Standard version (ISO)
87744428A − 11 − 2007
34
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
**
29
* **
Version with Power Shuttle (ISO) Standard version (North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
35
*
30
*
Version with Power Shuttle (North America)
87744428A − 11 − 2007
36
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
31
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
37
32
87744428A − 11 − 2007
38
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
33
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
39
34
87744428A − 11 − 2007
40
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
35
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
41
36
87744428A − 11 − 2007
42
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
37
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
43
38
87744428A − 11 − 2007
44
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
39
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
45
*
**
40
* **
Standard version (ISO − North America) and with Power Shuttle (ISO) Version with Power Shuttle (North America)
87744428A − 11 − 2007
46
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
*
41
*
Only for version with Power Shuttle (ISO − North America)
87744428A − 11 − 2007
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
47
*
42
*
Only for version with Power Shuttle (ISO − North America)
87744428A − 11 − 2007
48
SECTION 55 − ELECTRICAL SYSTEM − CHAPTER 6
43
87744428A − 11 − 2007
SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
1
SECTION 90 − PLATFORM, CAB, BODYWORK Chapter 1 − Bodywork CONTENTS
Section
Description
Page
90 100 22
Bonnet. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
90 100 80
Protective grill. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
90 110 50
Dashboard. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
90 114 26
Rear roll bar. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
90 116 10
Right or left−hand mudguard. Removal − Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
90 116 24
Rear guard. Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
87744428A − 11 − 2007
2
SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
OP. 90 100 22 BONNET Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Disconnect the electrical connections (1) of the front headlamps.
1
2. Unscrew the retaining bolts holding the pivot bracket (1) to the engine.
2 3. Remove the retaining spring and shock absorber (1) from the upper pivot and remove the bonnet. 4. To refit the bonnet, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. −
Position the bonnet and secure the shock absorber by means of the clip.
−
Fit the pivot bracket on the engine.
−
Connect the electrical connections of the front headlamps.
87744428A − 11 − 2007
3
SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
3
Op. 90 100 80 PROTECTIVE GRILL Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows. 1. Remove the three retaining bolts (2), washers and the LH lateral grill (1).
27642
4
2. Remove the three retaining bolts (1), washers and the RH lateral grill (2). 3. To refit the grill, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
−
Fit the RH lateral grill, washers and the three retaining bolts.
27643
5 −
Fit the LH lateral grill, washers and the three retaining bolts.
87744428A − 11 − 2007
4
SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
Op. 90 110 50 DASHBOARD 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. Check that no one is in the vicinity of the load to be lifted.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. Proceed as follows. 1. Carry out operation 90 100 22 Bonnet, only removal (see section 2). 2. Carry out operation 90 100 84 Bonnet guard, only removal (see page 4). 3. Disconnect the engine oil pressure sensor connection (1). 6 4. Unscrew the speedometer/tachometer (2) control cable and the clamp (1).
7 5. Disconnect the two steering cylinder control pipes (1).
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6. Unscrew the clamp and remove the thermostarter piping (1).
9 7. Unscrew the brake fluid tank retaining bolts (2), remove the tank and attach to the RH handrail (1).
10 8. Unscrew the service brakes control piping (1).
11 9. Disconnect the engine electric connection (1).
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
10. Disconnect the thermostarter connection (1).
13 11. Disconnect the hydrostatic steering oil supply and discharge lines (1).
14 12. Disconnect the accelerator control cable (1) from the control lever.
15 13. Disconnect the gear clutch control tie−rod (1).
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14. Disconnect the rear transmission electrical system electrical connection (1).
17 15. Connect the dashboard to a hoist, allow the hoist to take the strain and unscrew the retaining bolts (1).
18 16. Using the hoist, remove the dashboard (1). 17. To refit the dashboard, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. −
Position and secure the dashboard.
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Connect the rear transmission electrical connection.
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Connect the gear clutch control tie−rod.
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Connect the accelerator control cable.
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Connect the hydrostatic steering supply and discharge lines. Connect the thermostarter and engine electrical connections.
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Connect the service brakes control piping.
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Position and secure the brake fluid tank.
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Connect and secure the thermostarter piping.
19 −
Connect the steering cylinder control piping.
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Connect and secure the speedometer/tachometer control cable.
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Connect the engine oil pressure sensor connection.
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Carry out operation 90 100 84 Bonnet guard, only installation (see page 4).
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Carry out operation 90 100 22 Bonnet, only installation (see page 2).
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Bleed the brakes (see section 33).
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
Op. 90 114 26 REAR ROLL BAR 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. Check that no one is in the vicinity of the load to be lifted.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
Proceed as follows. 1. Connect the rear roll bar to a hoist and allow the hoist to take the strain. 2. Disconnect the electrical connections (1) of the lights attached to the roll bar (on both sides). 20 3. Unscrew the mudguards retaining bolts (1) from the rear roll bar (on both sides).
21 4. Extract the retaining bolt and remove the multi− pole socket (1) and support bracket.
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5. Unscrew the retaining bolt (1) that holds the lift lever control panel to the rear roll bar.
23 6. Unscrew the retaining bolts that hold the rear roll bar to the final drive casing and remove the lower bracket (1) (on both sides).
24 7. Using the hoist, remove the rear roll bar (1). 8. To refit the rear roll bar, proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
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Position the roll bar and secure by means of the relative brackets and bolts.
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Fit the lift lever control panel.
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Position the multi−pole socket and attach the roll bar to the mudguards.
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Connect the electrical connections to the lights on the roll bar.
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Free the roll bar from the hoist.
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
Op. 90 116 10 RIGHT OR LEFT−HAND MUDGUARD Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
RH mudguard Proceed as follows: 1. Remove the Lift−O−Matic control cable from the lever.
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2. Unscrew the retaining bolts and remove the RH mudguard (1). 3. To refit the RH mudguard proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
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Position and secure the RH mudguard.
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Connect the Lift−O−Matic control cable. 27
Op. 90 116 10 RIGHT OR LEFT−HAND MUDGUARD Removal−Installation
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
LH mudguard Proceed as follows: 1. Unscrew the retaining bolts and remove the LH mudguard (1).
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
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2. Extract the retaining bolt and remove the multi− pole socket (1) and support bracket. 3. To refit the LH mudguard proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. −
Position the LH mudguard and the multi−pole socket and secure. 29
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
Op. 90 116 24 REAR GUARD Replacement
CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing − safety goggles, gloves and shoes.
Proceed as follows: 1. Carry out operation 90 116 10 Right or left−hand mudguard, only removal (both mudguards, see page 11). 2. Unscrew the PTO control lever knob (1).
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3. Disconnect the lift control lever (2) drive rods. 4. Disconnect single pole connection (1).
31 5. Unscrew the retaining bolts and remove the tool box (1), together with the relative support.
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6. Remove the control valve tie−rod (1) from both the external lever and the support bracket.
33 7. Unscrew the retaining bolt and remove the seat (1).
34 8. Unscrew the retaining bolts and remove the gear and range gear control levers (1 and 2). 9. Disconnect the differential lock control pedal (3) from the tie rod.
35 10. Disconnect the parking brake tie−rod (1).
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SECTION 90 − PLATFORM, CAB, BODYWORK − CHAPTER 1
11. Unscrew the retaining bolts and remove the rear guard (1). 12. To refit the rear guard proceed as follows.
CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.
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Position and secure the rear guard using the bolts.
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Connect the parking brake tie−rod.
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Connect the differential lock control rod.
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Assemble and secure the gear and range gear control levers.
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Assemble and secure the seat.
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Connect the control valves tie−rod.
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Assemble and secure the tool box.
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Connect the single pole socket connection.
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Fit the lift control lever tie−rods.
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Screw on the PTO control lever knob.
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Carry out operation 90 116 10 Right or left−hand mudguard, only installation (both mudguards, see page 11).
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