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TD80D, TD95D REPAIR MANUAL COMPLETE CONTENTS SECTION 00 - GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 10 - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SECTION 18 - CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 SECTION 21 - FRONT TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 SECTION 23 - FWD TRANSFER BOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 SECTION 25 - MFD AXLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 SECTION 27 - REAR TRANSMISSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SECTION 31 - POWER TAKE-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SECTION 33 - BRAKES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 SECTION 35 - HYDRAULIC SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 SECTION 41 - STEERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 SECTION 44 - FRONT AXLE AND WHEELS (2WD) . . . . . . . . . . . . . . . . . . . . . 19 SECTION 55 - ELECTRICAL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 SECTION 90 - PLATFORM, CAB, BODYWORK AND DECALS . . . . . . . . . . . 25

The following pages are the collation of the contents pages from each section and chapter of the TD80D, TD95D Tractor Repair manual. Complete Repair part # 87658938. The sections used through out all New Holland product Repair manuals may not be used for each product. Each Repair manual will be made up of one or several books. Each book will be labeled as to which sections are in the overall Repair manual and which sections are in each book. The sections listed above are the sections utilized for the TD80D, TD95D Tractors.

Â©

2007 CNH America LLC Printed In U.S.A.

87658943 4/07 1st Printing

SECTION 00 -- GENERAL BOOK 1 - 87658939

Chapter 1 -- General CONTENTS Section

Description

Page

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Health and Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Ecology and the Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Minimum Hardware Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Federal Emissions Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 California Emission Control Warranty Statement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Consumables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 1 -- Engine CONTENTS Section

Description

Page

Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

10 001 54

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 1 -- Engine (Continued) CONTENTS Section

Description

Page

Rotating Counterweight Dynamic Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Checks, Dimensions, and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Crankshaft, Main Bearings, and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Valve Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 10 102 70

Rotating Counterweight Dynamic Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Valve Guides . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 Valve Seats in Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Crankshaft Front Oil Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Valve Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 2 -- Cooling System CONTENTS Section

Description

Page

Water Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

10 402 30

Cooling System Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10 402 28

Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 3 -- Lubrication System CONTENTS Section

Description

Page

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 4 -- Fuel System CONTENTS Section

Description

Page

SECTION 10 -- ENGINE BOOK 1 - 87658939

Chapter 4 -- Fuel System (Continued) CONTENTS Section

Description

Page

Fuel Injector Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Checking Injector Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 10 246 14

Injection Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Checking the Fuel Injection Pump Timing with the Pump on the Tractor . . . . . . . 19 Lock-time the Fuel Injection Pump with the Pump Removed from the Tractor . . . 23 Fuel System Air Bleeding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 18 -- CLUTCH BOOK 1 - 87658939

Chapter 1 -- Clutch CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Main Clutch (11 in./11 in.) (Models TD80D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Main Clutch (12 in./12 in.) (Model TD95D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Valeo Clutches (11 in./11 in. and 12 in./12 in.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Longitudinal Section of Clutch -- Luk Clutches (11 in./11 in. and 12 in./12 in.) . . . . . 6 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 11 in./11 in. and 12 in./12 in. Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Checks, Measurements and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Dimensions of the Valeo 11 in./11 in. Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Dimensions of the Luk 11 in./11 in. Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Dimensions of the Valeo 12 in./12 in. Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Dimensions of the Luk 12 in./12 in. Dual Clutch . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Minimum Permissible Dimensions After Refacing 11 in./11 in. and 12 in./12 in. Dual Clutches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Valeo 11 in. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Luk 11 in. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Valeo 12 in. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Luk 12 in. Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Clutch Release Lever Coplanarity Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Main Clutch Control Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 PTO Clutch Linkage Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 21 -- FRONT TRANSMISSION BOOK 2 - 87658940

Chapter 1 -- 12 x 12 Transmission with Synchronized Mechanical Shuttle CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Synchronizer Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox/Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Synchronizer Reverser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch--Reverser Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 21 -- FRONT TRANSMISSION BOOK 2 - 87658940

Chapter 2 -- 20 x 12 Transmission with Synchronized Mechanical Shuttle and Creeper CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Synchronizer Reverser--Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Clutch Casing--Synchronizer Reverser and Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 23 -- FWD TRANSFER BOX BOOK 2 - 87658940

Chapter 1 -- FWD Transfer Box CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission Shafts and Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Drive Gear Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transfer Box, Unit Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 25 -- MFD AXLE BOOK 2 - 87658940

Chapter 1 -- Front Mechanical Axle CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Complete Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Steering Knuckle Pins and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Wheel Hub Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Limited-Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wheel Hub Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Bevel Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Front Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Determining Pinion Shaft Pre-load Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 31 Determining Pinion Shaft Position Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . 32 Pinion Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Differential Installation and Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Differential Bearing Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Sealing Compound Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Toe-in Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

SECTION 27 -- REAR TRANSMISSION BOOK 2 - 87658940

Chapter 1 -- Rear Axle and Transmission CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pinion and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rear Axle Transmission -- Gearbox Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Transmission-Gearbox Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gearbox Driving Shaft Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Differential Lock Engagement Sleeve Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 39 Pinion Shaft Positioning Adjustment Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Pinion Shaft Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Differential Bearings and Backlash of Ring and Pinion Teeth . . . . . . . . . . . . . . . . . . . . 43 Differential Planetary and Side Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Final Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly (Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly (Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 31 -- POWER TAKE-OFF BOOK 2 - 87658940

Chapter 1 -- Power Take-Off CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation of Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Independent PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ground Speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PTO Speed Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Single Lever PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting for Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 540 Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 540 RPM PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 540/1000 RPM PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 33 -- BRAKES BOOK 3 - 87658941

Chapter 1 -- Brakes CONTENTS Section

Description

Page

SECTION 35 -- HYDRAULIC SYSTEMS BOOK 3 - 87658941

Chapter 1 -- Hydraulic Systems CONTENTS Section

Description

Page

Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic System -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Auxiliary (Rear) Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Double-Acting Cylinder Lift Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Double-Acting Cylinder Lower Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Single-Acting Cylinder Lift Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Single-Acting Cylinder Lower Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Double-Acting Cylinder with Automatic Detent Release Lift Phase . . . . . . . . . . . . . . 8 Double-Acting Cylinder with Automatic Detent Release Lower Phase . . . . . . . . . . . 9 Rear Remote Valve Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control Lever Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Quick-Release Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Switching Between Single and Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mechanically Controlled Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fast Raise/Lower Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Principles of Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Principles of Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Principles of Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Principles of Draft and Position Control Combined . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic Lift Oil Flow (Lift Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic Lift Oil Flow (Neutral Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic Lift Oil Flow (Lowering Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Three-Point Hitch (Category I and II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Adjustable Length Top Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Right-Hand Lift Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Telescopic Lateral Stabilizer Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lower Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Left-Hand Lift Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 35 -- HYDRAULIC SYSTEMS BOOK 3 - 87658941

Chapter 2 -- Hydraulic System Overhaul CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mechanically Controlled Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Adjusting the HPL on a Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 HPL on the Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Position Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Draft Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Fast Raise/Lower Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Lift Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Lift Control Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 High-pressure (Lift) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 35 -- HYDRAULIC SYSTEMS BOOK 3 - 87658941

Chapter 2 -- Hydraulic System Overhaul (Continued) CONTENTS Section

Description

Page

Convertible Single/Double Acting Auxiliary Control Valve . . . . . . . . . . . . . . . . . . . . . . . 52 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Convertible Single/Double Acting Auxiliary Control Valve with Float Control and Detent Release . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Spool Binding Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Spool Leakage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Adjustment of the Auxiliary Control Valve Automatic Detent Release Pressure . . . . . 62

SECTION 41 -- STEERING BOOK 3 - 87658941

Chapter 1 -- Steering CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Pump C25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydrostatic Power Steering (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydrostatic Power Steering (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Manual Steering to Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Manual Steering to Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydrostatic Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 41 204 34

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Steering Control Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Checking the Hydrostatic Steering Pressure Relief Valve with Steering Control Valve Installed on Tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

41 206 20

Hydrostatic Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Steering Cylinder (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Steering Cylinder (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) BOOK 3 - 87658941

Chapter 1 -- Axle and Wheels CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 1 -- Instrument Cluster CONTENTS Section

Description

Page

Instrument Cluster Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Analog Instrument Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Warning and Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuel Level Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Tachometer and Hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Engine Coolant Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 2 -- Components CONTENTS Section

Description

Page

Electrical Components Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Instrument Console Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Lights Control Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Rear Hood Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Starter Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 In-Cab Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fender Mounted Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Heating and Air Conditioning Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Radio (where applicable) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Applicable Components, Sensors and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmitters and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 3 -- Starting System CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 3 -- Starting System (Continued) CONTENTS Section

Description

Page

Battery Positive Cable Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Starter Motor Ground Lead Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Battery Ground Cable Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 55 201 50

Starter Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

55 201 54

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starter Motor Tests and Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Armature Shaft End-Play . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Starter Motor Test Without Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Armature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Field Windings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Bearing Bushings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Driving Pinion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 4 -- Charging System CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 5 -- Battery CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Relative Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dry-Charged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Normal Charging (Top Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging Very Flat Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 55 -- ELECTRICAL SYSTEM BOOK 4 - 87658942

Chapter 6 -- Electrical Circuits CONTENTS Section

Description

Page

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Wire Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ground Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuses and Relays Main Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuses and Relay Box (Inside Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General Diagram - Center (With Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General Diagram - Center without Cab (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Direction Indicator and Hazard Warning Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Windscreen Washer/Wiper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Brake Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Heating and Air Conditioning Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ROPS Work Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Work Lamp (with Cab) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Parking/Headlights and Turn Signal Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Operator Presence Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Analogue Instrument Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS BOOK 4 - 87658942

Chapter 1 -- Cab CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Control Levers, Seat, Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear Window, Handle and Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lock and Exterior Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LH Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cab Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS BOOK 4 - 87658942

Chapter 2 -- Air Conditioning System CONTENTS Section

Description

Page

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Cab Heating and Ventilation Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Air Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Temperature Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Ignition Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Switching on the Air Conditioning and Temperature Control . . . . . . . . . . . . . . . . . . . . . 10 Air Conditioning and Temperature Control Button . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Heating Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 3--Speed Fan Control Knob . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Use of the Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Switching On the Air Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Switching Off the Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Components of the Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Receiver/Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Thermostatic Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Air Conditioner Temperature Cycling Control Switch . . . . . . . . . . . . . . . . . . . . . . . . 16 Thermostatic Switch (ANTIFROST) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Low Pressure Cut-out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Combined High/Low Pressure Cut--out Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS BOOK 4 - 87658942

Chapter 2 -- Air Conditioning System (Continued) CONTENTS Section

Description

Page

System Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Refrigerant Recovery--Recycling and Evacuation-Charging Stations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Function Testing of Cab Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Summary of the Air Conditioning System Charging Operations . . . . . . . . . . . . . . . . . . . . 27 Checking for Refrigerant Leaks Using an Electronic Leak Detector . . . . . . . . . . . . . . . . . 29 Maintenance of the Air Conditioning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Air Conditioning and Heating Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Receiver--Dryer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Compressor Oil -- Type and Quantity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Compressor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Tension Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Fitting the Compressor Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Checking Compressor Drive Belt Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Periodic Checking of Drive Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

SECTION 00 -- GENERAL -- CHAPTER 1

SECTION 00 - GENERAL Chapter 1 - General CONTENTS Section

Description

Page

SECTION 00 -- GENERAL -- CHAPTER 1 WARNING

WARNING

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.

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

WARNING Anyone who performs the operations described herein without strictly following the instructions is personally responsible for resulting injury or damage to property.

SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL INSTRUCTIONS IMPORTANT NOTICE All maintenance and repair operations described in this manual should be carried out exclusively by the authorized workshops. All instructions detailed should be carefully observed and special equipment indicated should be used if necessary. Everyone who carries out service operations described without carefully observing these directives will be directly responsible for resulting consequences.

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

ROTATING SHAFT SEALS To correctly install rotating shaft seals, observe the following instructions: •

Let the seal soak into the same oil as it will seal for at least half an hour before mounting;

•

Thoroughly clean the shaft and ensure that the shaft working surface is not damaged;

•

Place the sealing lip towards the fluid. In case of a hydrodynamic lip, consider the shaft rotation direction and orient grooves in order that they deviate the fluid towards the inner side of the seal;

•

Coat the sealing lip with a thin layer of lubricant (oil rather than grease) and fill the gap between the sealing lip and the dust lip of double lip seals with grease;

•

Insert the seal into its seat and press it down using a flat punch. Do not tap the seal with a hammer or a drift;

•

Take care to insert the seal perpendicular to its seat while you are pressing it. Once the seal is settled, ensure that it contacts the thrust element, if required;

•

To prevent damaging the sealing lip against the shaft, place a suitable protection during installation.

O RINGS Lubricate the O rings before inserting them into their seats. This will prevent the O rings from roll over and twisting during mounting, which will jeopardize sealing.

SEALERS Apply silicone/gasket eliminator over the mating surfaces marked with an X. Before applying the sealer, prepare the surface as follows: •

remove possible scales using a metal brush;

•

thoroughly degrease the surfaces using one of the following cleaning agents: trichlorethylene, diesel fuel or a water and soda solution.

BEARINGS It is advisable to heat the bearings to 80° to 90°C (176° to 194°F) before mounting them on their shafts and cool them down before inserting them into their seats with external tapping.

SPRING PINS When mounting split socket spring pins, ensure that the pin notch is oriented in the direction of the effort to stress the pin. Spiral spring pins should not be oriented during installation.

SECTION 00 -- GENERAL -- CHAPTER 1

GENERAL INSTRUCTIONS PRECAUTIONARY NOTICE Only authorized workshops should carry out maintenance and repair operations on the tractor, or tractor components. Carefully observe all instructions, safety precautions, and the use of equipment such as special tools, as detailed in this manual. Damage to the tractor, or injury to personnel is the direct responsibility of anyone who fails to observe these precautions.

EQUIPMENT NOTICE The equipment proposed in this manual is: •

Designed and studied expressly for use on New Holland tractors

•

Necessary for adequate and reliable repair of the tractor

•

Strictly tested for the efficient and long lasting life cycle of the tractor

SPARE PARTS NOTICE Genuine NEW HOLLAND spare parts guarantee the same quality, safety and life cycle as original components. These parts bear the logo:

GENERAL NOTICES In this manual, the description ’FRONT’, ’REAR’, ’RIGHT-HAND’ and ’LEFT-HAND’ refer to the view seen by the operator while in the operator’s seat, looking in the direction in which the tractor normally moves. Wear limits detailed in this manual, although advised, are not binding.

SECTION 00 -- GENERAL -- CHAPTER 1

HEALTH AND SAFETY CONTENTS Description

Page

HEALTH AND SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ACIDS AND ALKALIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ADHESIVES AND SEALERS - see Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 ANTIFREEZE - see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol. . . . . . . . . . . . . . . . . . . . . . . . 6 ARC WELDING - see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BATTERY ACIDS - see Acids and Alkalis. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) - see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 BRAZING - see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CHEMICAL MATERIALS - GENERAL - see Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DOâ&#x20AC;&#x2122;S . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 DO NOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 CORROSION PROTECTION MATERIALS - see Solvents, Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 DUSTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 ELECTRIC SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 EXHAUST FUMES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIBER INSULATION - see Dusts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRE - see Welding, Foams, Legal Aspects. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIRST AID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FOAMS - Polyurethane - see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FUELS - see Fire, Legal Aspects, Chemicals - General, Solvents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GAS CYLINDERS - see Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 GENERAL WORKSHOP TOOLS AND EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LEGAL ASPECTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LUBRICANTS AND GREASES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 PAINTS - see Solvents and Chemical Materials - General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLDER - see Welding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 SOLVENTS - see Chemical Materials - General Fuels (Kerosene), Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 SUSPENDED LOADS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 WELDING - see Fire, Electric Shock, Gas Cylinders. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 00 -- GENERAL -- CHAPTER 1

HEALTH AND SAFETY PRECAUTIONS Many of the procedures associated with vehicle maintenance and repair involve physical hazards or other risks to health. This section lists, alphabetically, some of these hazardous operations and the materials and equipment associated with them. The precautions necessary to avoid these hazards are identified. The list is not exhaustive and all operations and procedures and the handling of materials, should be carried out with health and safety in mind.

Skin contact with uncured resins and hardeners can result in irritation; dermatitis and absorption of toxic or harmful chemicals through the skin. Splashes can damage the eyes. Provide adequate ventilation and avoid skin and eye contact. Follow manufacturers instructions.

Anaerobic, Cyanoacrylate and other Acrylic Adhesives Many are irritant, sensitizing or harmful to the skin. Some are eye irritants.

ACIDS AND ALKALIS - see Battery acids, e.g.

Skin and eye contact should be avoided and the manufacturers instructions followed.

Used in batteries and cleaning materials.

Cyanoacrylate adhesives (super-glues) must not contact the skin or eyes. If skin or eye tissue is bonded cover with a clean moist pad and get medical attention. Do not attempt to pull tissue apart. Use in well ventilated areas as vapors can cause irritation of the nose and eyes.

caustic soda, sulfuric acid.

Irritant to the skin, eyes, nose and throat. Causes burns. Avoid splashes to the skin, eyes and clothing. Wear suitable protective gloves and goggles. Can destroy ordinary protective clothing. Do not breathe mists. Ensure access to water and soap is readily available for splashing accidents.

ADHESIVES AND SEALERS - see Fire Highly Flammable and combustible. Generally should be stored in â&#x20AC;&#x153;No Smokingâ&#x20AC;? areas; cleanliness and tidiness in use should be observed, e.g. disposable paper covering benches; should be dispensed from applicators where possible; containers, including secondary containers, should be labelled. Solvent based Adhesives/Sealers - See Solvents. Follow manufacturers instructions.

For two-pack systems see Resin based adhesives/ sealers.

Isocyanate (Polyurethane) Adhesives/ Sealers - see Resin based Adhesives. Individuals suffering from asthma or respiratory allergies should not work with or near these materials as sensitivity reactions can occur. Any spraying should preferably be carried out in exhaust ventilated booths removing vapors and spray droplets from the breathing zone. Individuals working with spray applications should wear supplied air respirators.

ANTIFREEZE - see Fire, Solvents e.g. Isopropanol, Ethylene Glycol, Methanol.

Water based Adhesives/Sealers

Highly Flammable and Combustible.

Those based on polymer emulsions and rubber lattices may contain small amounts of volatile toxic and harmful chemicals. Skin and eye contact should be avoided and adequate ventilation provided during use.

Used in vehicle coolant systems, brake air pressure systems, screenwash solutions.

Follow manufacturers instructions.

Antifreeze may be absorbed through the skin in toxic or harmful quantities. Antifreeze if swallowed is fatal and medical attention must be found immediately.

Resin based Adhesives/Sealers - e.g. epoxide and formaldehyde resin based. Mixing should only be carried out in well ventilated areas as harmful or toxic volatile chemicals may be released.

Vapors given off from coolant antifreeze (glycol) arise only when heated.

SECTION 00 -- GENERAL -- CHAPTER 1 ARC WELDING - see Welding. BATTERY ACIDS - see Acids and Alkalis.

The effects of excessive exposure to chemicals may be immediate or delayed; briefly experienced or permanent; cumulative; superficial; life threatening; or may reduce life-expectancy.

Gases released during charging are explosive. Never use naked flames or allow sparks near charging or recently charged batteries.

DOâ&#x20AC;&#x2122;S

BRAKE AND CLUTCH FLUIDS (Polyalkylene Glycols) - see Fire.

Do remove chemical materials from the skin and clothing as soon as practicable after soiling. Change heavily soiled clothing and have it cleaned.

Combustible. Splashes to the skin and eyes are slightly irritating. Avoid skin and eye contact as far as possible. Inhalation of vapor hazards do not arise at ambient temperatures because of the very low vapor pressure.

BRAZING - see Welding. CHEMICAL MATERIALS - GENERAL - see Legal Aspects.

Chemical materials such as solvents, sealers, adhesives, paints, resin foams, battery acids, antifreeze, brake fluids, oils and grease should always be used with caution and stored and handled with care. They may be toxic, harmful, corrosive, irritant or highly flammable and give rise to hazardous fumes and dusts.

Do carefully read and observe hazard and precaution warnings given on material containers (labels) and in any accompanying leaflets, poster or other instructions. Material health and safety data sheets can be obtained from Manufacturers. Do organize work practices and protective clothing to avoid soiling of the skin and eyes; breathing vapors/aerosols/dusts/fumes; inadequate container labelling; fire and explosion hazards. Do wash before job breaks; before eating, smoking, drinking or using toilet facilities when handling chemical materials. Do keep work areas clean, uncluttered and free of spills. Do store according to national and local regulations. Do keep chemical materials out of reach of children.

SECTION 00 -- GENERAL -- CHAPTER 1

DO NOTS

Cutting - see Welding.

Do Not mix chemical materials except under the manufacturers instructions; some chemicals can form other toxic or harmful chemicals; give off toxic or harmful fumes; be explosive when mixed together.

De-Waxing - see Solvents and Fuels (Kerosene).

Do Not spray chemical materials, particularly those based on solvents, in confined spaces e.g. when people are inside a vehicle. Do Not apply heat or flame to chemical materials except under the manufacturersâ&#x20AC;&#x2122; instructions. Some are highly flammable and some may release toxic or harmful fumes. Do Not leave containers open. Fumes given off can build up to toxic, harmful or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, pits, etc. Do Not transfer chemical materials to unlabeled containers. Do Not clean hands or clothing with chemical materials. Chemicals, particularly solvents and fuels will dry the skin and may cause irritation with dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Do Not use emptied containers for other materials, except when they have been cleaned under supervised conditions. Do Not sniff or smell chemical materials. Brief exposure to high concentrations of fumes can be toxic or harmful. Clutch Fluids - see Brake and Clutch Fluids. Clutch Linings and Pads - see Brake and Clutch Linings and Pads.

DUSTS Powder, dusts or clouds may be irritant, harmful or toxic. Avoid breathing dusts from powdery chemical materials or those arising from dry abrasion operations. Wear respiratory protection if ventilation is inadequate.

ELECTRIC SHOCK Electric shocks can result from the use of faulty electrical equipment or from the misuse of equipment even in good condition. Ensure that electrical equipment is maintained in good condition and frequently tested. Ensure that flexes, cables, plugs and sockets are not frayed, kinked, cut, cracked or otherwise damaged. Ensure that electric equipment is protected by the correct rated fuse. Never misuse electrical equipment and never use equipment which is in any way faulty. The results could be fatal. Use reduced voltage equipment (110 volt) for inspection and working lights where possible. Ensure that the cables of mobile electrical equipment cannot get trapped and damaged, such as in a vehicle hoist. Use air operated mobile equipment where possible in preference to electrical equipment. In cases of electrocution:-

CORROSION PROTECTION MATERIALS -

- switch off electricity before approaching victim

Highly flammable, flammable.

- if this is not possible, push or drag victim from source of electricity using dry non-conductive material

see Solvents, Fire.

These materials are varied and the manufacturers instructions should be followed. They may contain solvents, resins, petroleum products etc. Skin and eye contact should be avoided. They should only be sprayed in conditions of adequate ventilation and not in confined spaces.

- commence resuscitation if trained to do so - SUMMON MEDICAL ASSISTANCE

SECTION 00 -- GENERAL -- CHAPTER 1 EXHAUST FUMES These contain asphyxiating, harmful and toxic chemicals and particles such as carbon oxides, nitrogen oxides, aldehydes, lead and aromatic hydrocarbons. Engines should only be run under conditions of adequate extraction or general ventilation and not in confined spaces.

Splashes in the eye should be flushed with clean water for at least ten minutes. Soiled skin should be washed with soap and water. Inhalation affected individuals should be moved to fresh air immediately.

Gasoline (Petrol) Engine

If swallowed or if effects persist consult a doctor with information (label) on material used.

There may not be adequate warning in the form of odor or irritation before immediate and delayed toxic or harmful effects arise.

Do not induce vomiting (unless indicated by manufacturer).

Diesel Engine

FOAMS - Polyurethane - see Fire.

Soot, discomfort and irritation usually give adequate warning of hazardous fume concentrations.

Foam is used in sound and noise insulation. Cured foams are used in seat and trim cushioning. Follow manufacturers instructions.

FIBER INSULATION - see Dusts. Fiber insulation is used in noise and sound insulation. The fibrous nature of surfaces and cut edges can cause skin irritation. This is usually a physical and not a chemical effect. Precautions should be taken to avoid excessive skin contact through careful organization of work practices and the use of gloves.

FIRE - see Welding, Foams, Legal Aspects. Many of the materials found on or associated with the repair of vehicles are highly flammable. Some give off toxic or harmful fumes if burnt. Observe strict fire safety when storing and handling flammable materials or solvents, particularly near electrical equipment or welding processes. Before using electrical or welding equipment, take steps to eliminate all fire hazards. Have a suitable fire extinguisher available when using welding or heating equipment.

FIRST AID Apart form meeting any legal requirements it is desirable for someone in the workshop to be trained in first aid procedures.

Unreacted components are irritating and may be harmful to the skin and eyes. Wear gloves and goggles. Individuals with chronic respiratory diseases, asthma, bronchial medical problems or histories of allergic diseases should not work with or near uncured materials. The components, vapors, spray mists can cause direct irritation, sensitivity reactions and may be toxic or harmful. Vapors and spray mists must not be breathed. These materials must be applied with adequate ventilation and respiratory protection. Do not remove respirator immediately after spraying, wait until vapor/ mists have cleared. Burning of the uncured components and the cured foams can generate toxic and harmful fumes. Smoking, open flames or the use of electrical equipment during foaming operations and until vapors/mists have cleared should not be allowed. Any heat cutting of cured foams or partially cured foams should be conducted with extraction ventilation.

SECTION 00 -- GENERAL -- CHAPTER 1

FUELS - see Fire, Legal Aspects, Chemicals General, Solvents. Used as fuels and cleaning agents. Gasoline (Petrol). Highly flammable. Swallowing can result in mouth and throat irritation and absorption from the stomach can result in drowsiness and unconsciousness. Small amounts can be fatal to children. Aspiration of liquid into the lungs, e.g. through vomiting, is a very serious hazard. Gasoline dries the skin and can cause irritation and dermatitis on prolonged or repeated contact. Liquid in the eye causes severe smarting. Motor gasoline may contain appreciable quantities of benzene, which is toxic upon inhalation and the concentrations of gasoline vapors must be kept very low. High concentrations will cause eye, nose and throat irritation, nausea, headache, depression and symptoms of drunkenness. Very high concentrations will result in rapid loss of consciousness. Ensure there is adequate ventilation when handling and using gasoline. Great care must be taken to avoid the serious consequences of inhalation in the event of vapor build up arising from spillages in confined spaces.

if liquid aspiration into the lungs occurs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes in the eye may be slightly irritating. In normal circumstances the low volatility does not give rise to harmful vapors. Exposure to mists and vapors from kerosene at elevated temperatures should be avoided (mists may arise in de-waxing). Avoid skin and eye contact and ensure there is adequate ventilation. Gas-Oil (Diesel Fuel) - see Fuels (Kerosene). Combustible. Gross or prolonged skin contact with high boiling gas oils may also cause serious skin disorders including skin cancer. GAS CYLINDERS - see Fire. Gases such as oxygen, acetylene, carbon dioxide, argon and propane are normally stored in cylinders at pressures of up to 138 bar (2000 psi) and great care should be taken in handling these cylinders to avoid mechanical damage to them or to the valve gear attached. The contents of each cylinder should be clearly identified by appropriate markings.

Special precautions apply to cleaning and maintenance operations on gasoline storage tanks.

Cylinders should be stored in well ventilated enclosures, and protected from ice and snow, or direct sunlight. Fuel gases (e.g. acetylene and propane) should not be stored in close proximity to oxygen cylinders.

Gasoline should not be used as a cleaning agent. It must not be siphoned by mouth.

Care should be exercised to prevent leaks from gas cylinders and lines, and to avoid sources of ignition.

Kerosene (Paraffin)

Only trained personnel should undertake work involving gas cylinders.

Used also as heating fuel, solvent and cleaning agent.

Gases - see Gas Cylinders.

Flammable.

Gas Shielded Welding - see Welding.

Irritation of the mouth and throat may result from swallowing. The main hazard from swallowing arises

Gas Welding - see Welding.

SECTION 00 -- GENERAL -- CHAPTER 1 GENERAL WORKSHOP TOOLS AND EQUIPMENT It is essential that all tools and equipment are maintained in good condition and the correct safety equipment used where required. Never use tools or equipment for any purpose other than that for which they were designed. Never overload equipment such as hoists, jacks, axle and chassis stands or lifting slings. Damage caused by overloading is not always immediately apparent and may result in a fatal failure the next time that the equipment is used. Do not use damaged or defective tools or equipment, particularly high speed equipment such as grinding wheels. A damaged grinding wheel can disintegrate without warning and cause serious injury. Wear suitable eye protection when using grinding, chiselling or sand blasting equipment. Wear a suitable breathing mask when using sand blasting equipment, working with asbestos based materials or using spraying equipment. Glues - see Adhesives and Sealers. High Pressure Air, Lubrication and Oil Test Equipment - see Lubricants and Greases. Always keep high pressure equipment in good condition and regularly maintained, particularly at joints and unions. Never direct a high pressure nozzle at the skin as the fluid may penetrate to the underlying tissue etc. and cause serious injury.

LEGAL ASPECTS Many laws and regulations make requirements relating to health and safety in the use of materials and equipment in workshops. Workshops should be familiar, in detail, with these and associated laws and regulations. Consult local factory inspectorate if in any doubt.

LUBRICANTS AND GREASES Avoid all prolonged and repeated contact with mineral oils, especially used oils. Used oils contaminated during service (e.g. routine service change sump oils) are more irritating and more likely to cause serious effects including skin cancer in the event of gross and prolonged skin contact. Wash skin thoroughly after work involving oil. Proprietary hand cleaners may be of value provided they can be removed from the skin with water. Do not use petrol, paraffin or other solvents to remove oil from the skin. Lubricants and greases may be slightly irritating to the eyes. Repeated or prolonged skin contact should be avoided by wearing protective clothing if necessary. Particular care should be taken with used oils and greases containing lead. Do not allow work clothing to be contaminated with oil. Dry clean or launder such clothing at regular intervals. Discard oil soaked shoes.

SECTION 00 -- GENERAL -- CHAPTER 1

Do not employ used engine oils as lubricants or for any application where appreciable skin contact is likely to occur. Used oils may only be disposed of in accordance with local regulations.

Pressurized Equipment - see High Pressure Air, Lubrication and Oil Test Equipment.

Noise Insulation Materials - see Foams, Fiber Insulation.

Sealers - see Adhesives and Sealers.

PAINTS - see Solvents and Chemical Materials General.

SOLDER - see Welding.

Highly Flammable. One Pack. Can contain harmful or toxic pigments, driers and other components as well as solvents. Spraying should only be carried out with adequate ventilation. Two Pack. Can also contain harmful and toxic unreacted resins and resin hardening agents. The manufacturers instructions should be followed and the section of page 00-6 on resin based adhesives, isocyanate containing Adhesives and Foams should be consulted. Spraying should preferably be carried out in ventilated booths removing vapor and spray mists from the breathing zone. Individuals working in booths should wear respiratory protection. Those doing small scale repair work in the open shop should wear supplied air respirators. Paint Thinners - see Solvents. Petrol - see Fuels (Gasoline).

Resistance Welding - see Welding.

Solders are mixtures of metals such that the melting point of the mixture is below that of the constituent metals (normally lead and tin). Solder application does not normally give rise to toxic lead fumes, provided a gas/air flame is used. Oxy-acetylene flames should not be used, as they are much hotter and will cause lead fumes to be emitted. Some fumes may be produced by the application of any flame to surfaces coated with grease etc. and inhalation of these should be avoided. Removal of excess solder should be undertaken with care, to ensure that fine lead dust is not produced, which can give toxic effects if inhaled. Respiratory protection may be necessary. Solder spillage and filing should be collected and removed promptly to prevent general air contamination by lead. High standards of personal hygiene are necessary in order to avoid indigestion of lead or inhalation of solder dust from clothing.

SECTION 00 -- GENERAL -- CHAPTER 1 SOLVENTS - see Chemical Materials - General Fuels (Kerosene), Fire. e.g. Acetone, white spirit, toluene, xylene, trichlorethane. Used in cleaning materials, de-waxing, paints, plastics, resins, thinners etc. Highly Flammable. Skin contact will degrease the skin and may result in irritation and dermatitis following repeated or prolonged contact. Some can be absorbed through the skin in toxic or harmful quantities.

When the spraying material contains solvents, e.g. paints, adhesives, coatings, use extraction ventilation or personal respiratory protection in the absence of adequate general ventilation. Do not apply heat or flame except under specific and detailed manufacturers instructions. Sound Insulation - see Fiber Insulation, Foams. Spot Welding - see Welding.

SUSPENDED LOADS.

Splashes in the eye may cause severe irritation and could lead to loss of vision.

There is always a danger when loads are lifted or suspended. Never work under an unsupported suspended or raised load, e.g. jacked up vehicle, suspended engine, etc.

Brief exposure to high concentrations of vapors or mists will cause eye and throat irritation, drowsiness, dizziness, headaches and in the worst circumstances, unconsciousness.

Always ensure that lifting equipment such as jacks, hoists, axle stands, slings, etc. are adequate and suitable for the job, in good condition and regularly maintained.

Repeated or prolonged exposures to excessive but lower concentrations of vapors or mists, for which there might not be adequate warning indications, can cause more serious toxic or harmful effects.

Never improvise lifting tackle.

Aspiration into the lungs (e.g. through vomiting) is the most serious consequence of swallowing. Avoid splashes to the skin, eyes and clothing. Wear protective gloves, goggles and clothing if necessary. Ensure good ventilation when in use, avoid breathing fumes, vapors and spray mists and keep containers tightly sealed. Do not use in confined spaces.

Underseal - see Corrosion Protection. WELDING - see Fire, Electric Shock, Gas Cylinders. Welding processes include Resistance Welding (Spot Welding), Arc Welding and Gas Welding. Resistance Welding This process may cause particles of molten metal to be emitted at high velocity and the eyes and skin must be protected.

SECTION 00 -- GENERAL -- CHAPTER 1

Arc Welding This process emits a high level of ultraviolet radiation which may cause eye and skin burns to the welder and to other persons nearby. Gas-shielded welding processes are particularly hazardous in this respect. Personal protection must be worn, and screens used to shield other people. Metal spatter will also occur and appropriate eye and skin protection is necessary. The heat of the welding arc will produce fumes and gases from the metals being welded and from any applied coatings or contamination on the surfaces being worked on. These gases and fumes may be toxic and inhalation should always be avoided. The use of extraction ventilation to remove the fumes from the working area may be necessary, particularly in cases where the general ventilation is poor, or where considerable welding work is anticipated. In extreme cases where adequate ventilation cannot be provided, supplied air respirators may be necessary. Gas Welding Oxy-acetylene torches may be used for welding and cutting and special care must be taken to prevent leakage of these gases, with consequent risk of fire and explosion.

The process will produce metal spatter and eye and skin protection is necessary. The flame is bright and eye protection should be used, but the ultra-violet emission is much less than that from arc welding, and lighter filters may be used. The process itself produces few toxic fumes, but such fumes and gases may be produced from coatings on the work, particularly during cutting away of damaged body parts and inhalation of the fumes should be avoided. In brazing, toxic fumes may be emitted from the metals in the brazing rod, and a severe hazard may arise if brazing rods containing cadmium are used. In this event particular care must be taken to avoid inhalation of fumes and expert advice may be required. SPECIAL PRECAUTIONS MUST BE TAKEN BEFORE ANY WELDING OR CUTTING TAKES PLACE ON VESSELS WHICH HAVE CONTAINED COMBUSTIBLE MATERIALS, E.G. BOILING OR STEAMING OUT OF FUEL TANKS. White Spirit - see Solvents.

SECTION 00 -- GENERAL -- CHAPTER 1

PRECAUTIONARY STATEMENTS PERSONAL SAFETY Throughout this manual and on machine decals, you will find precautionary statements (“DANGER”, “WARNING”, and “CAUTION”) followed by specific instructions. These precautions are intended for the personal safety of you and those working with you. Please take the time to read them.

DANGER This word “DANGER” indicates an immediate hazardous situation that, if not avoided, will result in death or serious injury. The color associated with Danger is RED.

WARNING This word “WARNING” indicates a potentially hazardous situation that, if not avoided, could result in death or serious injury. The color associated with Warning is ORANGE.

CAUTION This word “CAUTION” indicates a potentially hazardous situation that, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. The color associated with Caution is YELLOW.

FAILURE TO FOLLOW THE “DANGER”, “WARNING”, AND “CAUTION” INSTRUCTIONS MAY RESULT IN SERIOUS BODILY INJURY OR DEATH.

MACHINE SAFETY The precautionary statement (“IMPORTANT”) is followed by specific instructions. This statement is intended for machine safety. IMPORTANT: The word “IMPORTANT” is used to inform the reader of something he needs to know to prevent minor machine damage if a certain procedure is not followed.

INFORMATION NOTE: Instructions used to identify and present supplementary information.

ASAE S441.3 FEB04 ISO 11684

SECTION 00 -- GENERAL -- CHAPTER 1

SAFETY PRECAUTIONARY STATEMENTS A careful operator is the best operator. Most accidents can be avoided by observing certain precautions. To help prevent accidents, read the following precautions before operating this equipment. Equipment should be operated only by those who are responsible and instructed to do so. Carefully review the procedures given in this manual with all operators. It is important that all operators be familiar with and follow safety precautions.

THE TRACTOR 1. Read the Operator’s Manual carefully before using the tractor. Lack of operating knowledge can lead to accidents. 2. Only allow properly trained and qualified persons to operate the tractor. 3. To prevent falls, use the handrails and step plates when getting on and off the tractor. Keep steps and platform clear of mud and debris. 4. Do not permit anyone but the operator to ride on the tractor unless a passenger seat is fitted. There is no safe place for extra riders otherwise. 5. Replace all missing, illegible or damaged safety decals. 6. Keep safety decals free of dirt or grime. 7. Do not modify or alter or permit anyone else to modify or alter the tractor or any of its components or any tractor function without first consulting your dealer. 8. Tractor wheels are very heavy. Handle with care and ensure, when stored, that they cannot fall.

DRIVING THE TRACTOR 1. Always sit in the drivers seat while starting or driving the tractor. 2. When driving on public roads, have consideration for other road users. Pull off the road occasionally to allow any following traffic to pass. Do not exceed the legal speed limit set in your area. 3. Use low beam lights when meeting a vehicle at night. Make sure the lights are adjusted to prevent blinding the driver of an oncoming vehicle 4. Reduce speed before turning or applying the brakes. Ensure that both brake pedals are locked together when traveling at road speeds or when

on public roads. Brake both wheels simultaneously when making an emergency stop. 5. Use extreme caution and avoid hard application of the tractor brakes when towing heavy loads at road speeds. 6. Any towed vehicle whose total weight exceeds that of the towing tractor must be equipped with brakes for safe operation. 7. Never apply the differential lock when turning. When engaged, the differential lock will prevent the tractor from turning. 8. Always check overhead clearance, specifically when transporting the tractor. Watch where you are going, especially at low overhanging obstacles. 9. Use extreme caution when operating on steep slopes. 10. To avoid overturns, drive the tractor with care and at speeds compatible with safety, especially when operating over rough ground, when crossing ditches or slopes and when turning. 11. If the tractor becomes stuck or the tires are frozen to the ground, reverse the tractor out to prevent corners. 12. Keep the tractor in the same gear when going downhill as would be used when going uphill. Do not coast or freewheel down hills.

OPERATING THE TRACTOR 1. Apply the parking brake, place the PTO control in the ‘OFF’ position, the lift control lever in the down position, the remote control valve levers in the neutral position and the transmission lever in neutral before starting the tractor. 2. Do not start the engine or operate controls while standing beside the tractor. Always sit in the tractor seat when starting the engine or operating the controls.

SECTION 00 -- GENERAL -- CHAPTER 1 3. Do not bypass the neutral start switches. Consult your authorized dealer if your neutral start controls malfunction. Use jump cables only in the recommended manner. Improper use can result in a tractor runaway. 4. Avoid accidental contact with the gear shift levers while the engine is running. Unexpected tractor movement can result from such contact. 5. Do not get off the tractor while it is in motion. 6. Shut off the engine and PTO and apply the parking brake before getting off the tractor. 7. Do not park the tractor on a steep incline. 8. Do not run the tractor engine in an enclosed building without adequate ventilation. Exhaust fumes are toxic and can cause death. 9. Always wear a protective mask when working with toxic spray chemicals. Follow the directions on the chemical container. 10. If the power steering or engine ceases operating, stop the tractor immediately as the tractor will be more difficult to control. 11. Stop the engine and relieve pressure before connecting or disconnecting hydraulic, steering or fuel lines. 12. Tighten all connections before starting the engine or pressurizing lines. 13. Pull only from the swinging drawbar or the lower link drawbar in the lowered position . Use only a drawbar pin that locks in place. Pulling from the tractor rear axle or any point above the axle may cause the tractor to overturn. 14. If the front end of the tractor tends to rise when heavy implements are attached to the threepoint hitch, install front end or front wheel weights. Do not operate the tractor with a light front end. 15. Always select Position Control when attaching implements and when transporting equipment. Be sure hydraulic couplers are properly installed and will disconnect safely in case of accidental detachment of the implement. 16. Do not leave equipment in the raised position when the vehicle is stopped or unattended. 17. Ensure any attached equipment or accessories are correctly installed, are approved for use with the tractor, do not overload the tractor and are operated and maintained in accordance with the instructions issued by the equipment or accessory manufacturer. 18. Remember that your tractor, if abused or incorrectly used, can be dangerous and become

a hazard both to the operator and to bystanders. Do not overload or operate with attached equipment which is unsafe, not designed for the particular task or is poorly maintained. 19. The tractor is designed to provide the minimum noise level at the operatorâ&#x20AC;&#x2122;s ears and meets or exceeds applicable standards in this respect. However, noise (sound pressure level) in the workplace can exceed 86 dB(A) when working between buildings or in confined spaces. Therefore, it is recommended that operators wear suitable ear protectors during vehicle operation.

OPERATING THE PTO 1. When operating PTO driven equipment, shut off the engine and wait until the PTO stops before getting off the tractor and disconnecting the equipment. 2. Do not wear loose clothing when operating the power take-off or especially when near rotating equipment. 3. When operating stationary PTO driven equipment, always apply the tractor parking brake and block the rear wheels front and back. 4. To avoid injury, do not clean, adjust, unclog or service PTO driven equipment when the tractor engine is running. 5. Make sure the PTO guard is in position at all times and always replace the PTO cap when the PTO is not in use.

SERVICING THE TRACTOR 1. The cooling system operates under pressure which is controlled by the radiator cap. It is dangerous to remove the cap while the system is hot. Always turn the cap slowly to the first stop and allow the pressure to escape before removing the cap entirely. 2. Do not smoke while refueling the tractor. Keep any type of open flame away. Wait for the engine to cool before refueling. 3. Keep the tractor and equipment, particularly brakes and steering, maintained in a reliable and satisfactory condition to ensure your safety and comply with legal requirements. 4. To prevent fire or explosion, keep open flames away from battery or cold weather starting aids. To prevent sparks which could cause explosion, use jumper cables according to instructions. 5. Stop the engine before performing any service on the tractor.

SECTION 00 -- GENERAL -- CHAPTER 1

6. Escaping diesel/hydraulic fluid under pressure can penetrate the skin causing serious injury.

5. Do not fill the fuel tank to capacity. Allow room for expansion.

Do not use your hand to check for leaks. Use a piece of cardboard or paper to search for leaks. • Stop the engine and relieve pressure before connecting or disconnecting lines. • Tighten all connections before starting the engine. • If fluid is injected into the skin obtain medical attention immediately. 7. Do not modify or alter or permit anyone else to modify or alter the tractor or any of its components or any tractor function without first consulting an authorized dealer.

6. Wipe up spilled fuel immediately.

8. The fuel oil in the injection system is under high pressure and can penetrate the skin. Unqualified persons should not remove or attempt to adjust a pump, injector, nozzle or any other part of the injection system. Failure to follow these instructions can result in serious injury.

ROPS

9. Continuous long term contact with used engine oil my cause skin cancer. Avoid prolonged contact with used engine oil. Wash skin promptly with soap and water.

1. Do not modify, drill, weld or alter the ROPS in any way.

•

DIESEL FUEL 1. Under no circumstances should gasoline, alcohol or blended fuels be added to diesel fuel. These combinations can create an increased fire or explosive hazard. In a closed container such as a fuel tank these blends are more explosive than pure gasoline. Do not use these blends.

7. Always tighten the fuel tank cap securely. 8. If the original fuel tank cap is lost, replace it with an approved cap. A non-approved cap may not be safe. 9. Keep equipment clean and properly maintained. 10. Do not drive equipment near open fires. 11. Never use fuel for cleaning purposes. 12. Arrange fuel purchases so that summer grade fuels are not used in the winter.

The tractor may be equipped with a safety frame (ROPS) which must be maintained in a serviceable condition. Be careful when driving through doorways or working in confined spaces with low headroom.

2. Never attempt to straighten or weld the ROPS or retaining brackets, which have suffered damage. By doing so you may weaken the structure and endanger your safety. 3. Do not secure any parts on the ROPS or attach it with other than the special high tension bolts and nuts specified. 4. Never attach chains or ropes to the safety frame or roll bar for pulling purposes.

2. Never remove the fuel cap or refuel with the engine running or hot.

5. Never take unnecessary risks even though your safety frame or roll bar affords you the maximum protection possible.

3. Do not smoke while refueling the tractor or when standing near fuel. Keep any type of open flame away. Wait for the engine to cool before refueling.

6. Whenever possible, operate with the ROPS in its fully upright and locked position.

4. Maintain control of the fuel filter pipe nozzle when filling the tank.

SECTION 00 -- GENERAL -- CHAPTER 1

ECOLOGY AND THE ENVIRONMENT Soil, air, and water are vital factors of agriculture and life in general. When legislation does not yet rule the treatment of some of the substances which are required by advanced technology, common sense should govern the use and disposal of products of a chemical and petrochemical nature.

2. Avoid skin contact with all fuels, oils, acids, solvents, etc. Most of them contain substances which may be harmful to your health.

The following are recommendations which may be of assistance:

4. Avoid spillage when draining off used engine coolant mixtures, engine, gearbox and hydraulic oils, brake fluids, etc. Do not mix drained brake fluids or fuels with lubricants. Store them safely or dispose of in a proper way to comply with local legislation and available resources.

â&#x20AC;˘

Become acquainted with and ensure that you understand the relative legislation applicable to your country. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, antifreeze, cleaning agents, etc., with regard to effect on man and nature and how to safely store, use and dispose of these substances. Agricultural consultants will, in many cases, be able to help you as well.

PRECAUTIONS 1. Avoid filling tanks using cans or inappropriate pressurized fuel delivery systems which may cause considerable spillage.

3. Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems.

5. Modern coolant mixtures, i.e. antifreeze and other additives, should be replaced every two years. Do not allow seepage into the soil. Collect and dispose of safely. 6. Repair any leaks or defects in the engine cooling or hydraulic system immediately. 7. Do not increase the specified operating pressure in a pressurized circuit as this may lead to component failure. 8. Protect hoses during welding as penetrating weld splatter may burn or weaken the hose, allowing the loss of oils, coolant, etc.

SECTION 00 -- GENERAL -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

METRIC NON-FLANGED HARDWARE AND LOCKNUTS CLASS 5.8

CLASS 8.8

CLASS 10.9

PLATED W/ZnCr

UNPLATED

PLATED W/ZnCr

LOCKNUT CL.8 W/CL8.8 BOLT

2.6 (23)*

3.4 (30)*

3.7 (33)*

4.8 (42)*

2.3 (20)*

7.6 (67)*

8.9 (79)*

12 (102)*

13 (115)*

17 (150)*

7.8 (69)*

14 (124)*

18 (159)*

22 (195)*

28 (248)*

31 (274)*

40 (354)*

19 (169)*

M10

28 (21)

36 (27)

43 (32)

56 (41)

61 (45)

79 (58)

38 (28)

M12

49 (36)

63 (46)

75 (55)

97 (72)

107 (79)

138 (102)

66 (49)

M16

121 (89)

158 (117)

186 (137)

240 (177)

266 (196)

344 (254)

164 (121)

M20

237 (175)

307 (226)

375 (277)

485 (358)

519 (383)

671 (495)

330 (243)

M24

411 (303)

531 (392)

648 (478)

839 (619)

897 (662)

1160 (855)

572 (422)

NOMINAL SIZE

UNPLATED

PLATED W/ZnCr

1.7 (15)*

2.2 (19)*

5.8 (51)*

UNPLATED

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION HEX CAP SCREW AND CARRIAGE BOLTS CLASSES 5.6 AND UP MANUFACTURER’S IDENTIFICATION

PROPERTY CLASS

HEX NUTS AND LOCKNUTS CLASSES 05 AND UP MANUFACTURER’S IDENTIFICATION

86529681 REV F 5.1

PROPERTY CLASS

CLOCK MARKING

SECTION 00 -- GENERAL -- CHAPTER 1

MINIMUM HARDWARE TIGHTENING TORQUES IN NEWTON-METERS (FOOT POUNDS) FOR NORMAL ASSEMBLY APPLICATIONS

INCH NON-FLANGED HARDWARE AND LOCKNUTS SAE GRADE 2 NOMINAL UNPLATED SIZE or PLATED SILVER 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

6.2 (55)* 13 (115)* 23 (17) 37 (27) 57 (42) 81 (60) 112 (83) 198 (146) 193 (142) 289 (213)

SAE GRADE 5

PLATED W/ZnCr

GOLD

UNPLATED or PLATED SILVER

8.1 (72)* 17 (149)* 30 (22) 47 (35) 73 (54) 104 (77) 145 (107) 256 (189) 248 (183) 373 (275)

9.7 (86)* 20 (178)* 35 (26) 57 (42) 87 (64) 125 (92) 174 (128) 306 (226) 495 (365) 742 (547)

13 (112)* 26 (229)* 46 (34) 73 (54) 113 (83) 163 (120) 224 (165) 397 (293) 641 (473) 960 (708)

GOLD

SAE GRADE 8 UNPLATED or PLATED SILVER

LOCKNUTS

PLATED W/ZnCr GOLD

GR.B w/GR5 BOLT

14 (121)* 18 (157)* 8.5 (75)* 28 (250)* 37 (324)* 17.5 (155)* 50 (37) 65 (48) 31 (23) 80 (59) 104 (77) 50 (37) 123 (91) 159 (117) 76 (56) 176 (130) 229 (169) 111 (82) 244 (180) 316 (233) 153 (113) 432 (319) 560 (413) 271 (200) 698 (515) 904 (667) 437 (323) 1048 (773) 1356 (1000) 654 (483)

GR.C w/GR8 BOLT

NOMINAL SIZE

12.2 (109)* 25 (220)* 44 (33) 71 (53) 108 (80) 156 (115) 215 (159) 383 (282) 617 (455) 924 (681)

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

NOTE: Torque values shown with * are inch pounds.

IDENTIFICATION CAP SCREWS AND CARRIAGE BOLTS

SAE GRADE 2

SAE GRADE 5

SAE GRADE 8 REGULAR NUTS

SAE GRADE 5 HEX NUTS

SAE GRADE 8 HEX NUTS

LOCKNUTS

GRADE IDENTIFICATION

GRADE A NO NOTCHES

GRADE A NO MARKS

GRADE B ONE CIRCUMFERENTIAL NOTCH

GRADE B THREE MARKS

GRADE C TWO CIRCUMFERENTIAL NOTCHES

GRADE C SIX MARKS MARKS NEED NOT BE LOCATED AT CORNERS

86529681 REV F 5.2

GRADE A NO MARK GRADE B LETTER B GRADE C LETTER C GRADE IDENTIFICATION

SECTION 00 -- GENERAL -- CHAPTER 1

FEDERAL EMISSIONS WARRANTY (North America Only) (California owner’s emissions warranty is covered elsewhere) CNH UK Ltd warrants that your new 1996 and later heavy-duty off-road diesel engine was designed, built, and equipped to conform to applicable U.S. Environmental Protection Agency regulations for a period of use of five years or 3,000 hours of operation, whichever occurs first. The new model year, class of diesel engine, and emission application determination for your engine are identified on the emission control information label affixed to the engine. The warranty period begins on the date the new equipment is sold to the first retail purchaser. Any emission control system parts which are proven defective during normal use will be repaired or replaced during the warranty period. The warranty repairs and service will be performed by any authorized CNH dealer at the dealer’s place of business, with no charge for parts or labor (including diagnosis). As the engine owner, you are responsible to perform all the required maintenance listed in your owner’s manual. CNH UK Ltd will not deny an emission warranty claim solely because you have no record of maintenance; however, a claim may be denied if your failure to perform maintenance resulted in the failure of a warranted part. Receipts covering regular maintenance should be retained in the event of questions and these receipts should be passed on to each subsequent owner of the engine. It is recommended replacement parts used for maintenance or repairs be CNH Service Parts to maintain the quality originally designed into your emission certified engine. The use of non-CNH parts does not invalidate the warranty on other components unless the use of such parts causes damage to warranted parts. CNH UK Ltd wishes to assure the emission control systems warranty is being properly administered. If you believe you have not received the service entitled to under this warranty, you should contact the nearest CNH Office for assistance. The address and phone number of each Office is in your equipment owner’s manual. If additional assistance or information is needed, contact: Service Department CNH America, LLC 500 Diller Avenue New Holland, PA 17557 (717) 355-1121 Please note that the Emission Warranty does not cover: 1. Systems and parts that were not first installed on the new equipment or engine as original equipment by CNH UK Ltd. 2. Part malfunctions caused by abuse, misuse, improper adjustment, modification, alteration, tampering, disconnection, improper or inadequate maintenance, or use of non-recommended fuels and lubricating oils. 3. Accident caused damage, acts of nature, or other events beyond CNH UK Ltd’s control. 4. Replacement of expendable items made in connection with scheduled maintenance. 5. Parts requiring replacement, inspection or adjustment maintenance intervals for reasons other than being defective. 6. Parts which are not CNH Service Parts. 7. Loss of time, inconvenience, loss of use of equipment/engine or commercial loss. 8. Equipment with altered or disconnected hourmeter where the hours cannot be determined. 9. Equipment normally operated outside the United States. 10. Non-defective parts replaced by other than CNH dealers.

Coverage This emission control system warranty applies only to the following emission control parts. Electronic Control Unit Fuel Injection Pump Fuel Injectors Turbocharger Intake Manifold Exhaust Manifold Boost Pressure Tubing-connection to Aneroid Device ON F.I.P.

SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT (North America Only) (California Only)

Your Warranty Rights and Obligations The California Air Resources Board and CNH UK LTD are pleased to explain the emission control system warranty on your engine. In California, new 2004 and later heavy-duty off-road engines from 50 to 750 HP must be designed, built and equipped to meet the State’s stringent anti-smog standards. CNH UK LTD must warrant the emission control system on your engine for the periods of time listed below, provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system includes parts such as the fuel injection system and the air induction system. Where a warrantable condition exists, CNH UK LTD will repair your heavy-duty off-road engine at no cost to you including diagnosis, parts and labor.

Manufacturer’s Warranty Coverage: The 2004 and later heavy-duty off-road engines are warranted from the original date of delivery for five years or 3000 hours of operation, whichever occurs first. If any emission-related part on your engine is defective, the part will be repaired or replaced by CNH UK LTD.

Owner’s Warranty Responsibilities: • • • • • • • •

As the heavy-duty off-road engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. CNH UK LTD recommends that you retain all receipts covering maintenance on your heavy-duty off-road engine, but CNH UK LTD cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance. As the heavy-duty off-road engine owner, you should, however, be aware that CNH UK LTD may deny you warranty coverage if your heavy-duty off-road engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications. Your engine is designed to operate on commercially available diesel fuel only. Use of any other fuel may result in your engine no longer operating in compliance with California’s emissions requirements. You are responsible for initiating the warranty process. The ARB suggests that you present your heavy-duty off-road engine to a CNH dealer as soon as a problem exists. The warranty repairs should be completed by the dealer as expeditiously as possible. If you have any questions regarding your warranty rights and responsibilities, you should contact your nearest CNH Office at the address and telephone number listed on the Owner Assistance page of your equipment’s operator manual. Prior to the expiration of the warranty, you must give notice of any failure of an emission control warranted part. Such notice must be given to CNH UK LTD or an authorized CNH dealer, and you must deliver the engine to the repair location. You, the owner, are responsible for incidental costs incurred by yourself or your employees as a result of an unwarrantable failure. Examples of such costs are communication expenses, meals and lodging. The owner is responsible for any business costs or losses, any “downtime” expenses and any “cargo” damage which result from the failure of a warranted part. CNH UK LTD is not responsible for other incidental or consequential damages, including, but not limited to fines, theft, vandalism or collisions.

Parts covered: This emission control system warranty applies to the following emission control parts: Electronic Control Unit Intake Manifold Fuel Injection Pump Charge Air Cooler Fuel Injectors Exhaust Manifold Turbocharger Boost Pressure Tubing (connection to Aneroid Device on F.I.P.) Any replacement part, equivalent in performance and durability, may be used in the performance of any maintenance or repairs and must be provided without charge to the owner. The use of these parts does not reduce the warranty obligations of CNH UK LTD. However, CNH UK LTD recommends the use of new, genuine CNH service parts or CNH approved rebuilt parts and assemblies. CNH UK LTD also recommends that the engine be serviced by a CNH authorized dealer.

CNH UK LTD Responsibilities: Warranty work will be provided at no charge to the owner at any authorized dealer, using genuine CNH service parts or CNH approved rebuilt parts or assemblies. The owner will not be charged for diagnostic labor which leads to the determination that a warranted part is defective, if the diagnostic work was performed at a warranty station. CNH UK LTD is liable for damages to other engine components caused by the failure under warranty of any warranted part.

Warranty Limitations CNH UK LTD is not responsible for failures resulting from abuse or neglect by owner or operator. CNH UK LTD warrants to the ultimate purchaser and each subsequent purchaser that the engine is designed, built, and equipped so as to conform with all applicable regulations adopted by the Air Resources Board, and that it is free from defects in materials and workmanship which cause the failure of a warranted part. Any warranted part which is not scheduled for replacement as required maintenance, or which is scheduled only for regular inspection to the effect of “repair or replace as necessary” is warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time prior to the first scheduled replacement point of that part. CNH UK LTD is not liable to warrant failures caused by the use of add-on or modified parts. CNH UK LTD is concerned to ensure proper maintenance of the engine to maximise emissions performance. Information on care and replacement of engine air cleaner, and all other aspects of engine maintenance is provided in a manual supplied to the owner. A maintenance schedule chart is provided in the manual.

SECTION 00 -- GENERAL -- CHAPTER 1

CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

SECTION 00 -- GENERAL -- CHAPTER 1

CONSUMABLES QTY Liters (US gal)

NEW HOLLAND RECOMMENDED PRODUCTS

Cooling system: - without cab: TD80D, TD95D, TD95D (HC) . . . . - with cab: TD80D, TD95D, TD95D (HC) . . . .

14.0 (3.7)

Fleetguard Compleat concentrate and water 50% and 50%

Windscreen washer bottle . . . . . . . . . .

2.0 (0.5)

COMPONENT TO BE FILLED OR TOPPED UP

Fuel tank TD80D, TD95D . . . . . . . . . . . . . . . . . . . TD95 (high clearance) . . . . . . . . . . . . .

16.0 (4.2)

92.0 (24.3) 74.0 (19.15) 26.9 (7.1)

INTERNATIONAL SPECIFICATION Ethylene Glycol concentrate and water 50% and 50%

Water and cleaning fluid Decanted and filtered diesel fuel

AMBRA Supergold SAE 15W-40 (NH330G) AMBRA Supergold SAE 10W-30 (NH324G)

API CF-4/SG CCMC D4 MIL-L-2104E

AMBRA Brake LHM oil (NH610A)

ISO 7308

(Auxiliary tank)

Engine sump: without filter : TD80D, TD95D, TD95D (HC) . . . .

10.5 (2.8)

with filter : TD80D, TD95D, TD95D (HC) . . . .

11.2 (3.0)

Brake control circuit . . . . . . . . . . . . . . . .

0.4 (0.1)

Hydrostatic steering circuit . . . . . . . . . .

2.0 (0.5)

Front axle: - axle housing: TD80D, TD95D, TD95D (HC) . . . . - final drives (each): TD80D, TD95D, TD95D (HC) . . . .

7.0 (1.8)

Rear transmission (bevel drive, final drives and brakes), transmission, hydraulic lift, PTO and hydrostatic steering: TD80D, TD95D, TD95D (HC) . . . . - with synchro-reverser: All Models . . . . . . . . . . . . . . . . . . . . .

1.25 (0.3)

Oil AKCELA MULTI G (NH410B)

API GL4 ISO 32/46 SAE 10W-30

Grease AMBRA GR8 (NH710A)

NLGI 2

55.0 (13.1) 55.0 (13.1)

Front wheel hubs . . . . . . . . . . . . . . . . . .

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

*See page 26 for information about using biodegradable oil in the transmission, axles, hubs and hydraulic system. IMPORTANT: Use only heavy-duty, low silicate coolant such as NH Fleetguard Compleat. Automotive antifreeze purchased at local supply store outlets most likely is not low silicate and must not be used in heavy-duty diesel engines. Always have a minimum of 50% ethylene glycol coolant in the cooling system, adjusting the concentration based on ambient temperature, according to coolant label instructions. Use good quality water. Deionized water is ideal for cooling systems and is contained in some prepackaged coolants labeled as pre-mixed with water. If the low silicate ethylene glycol coolant is not pre-charged with supplemental diesel coolant additive/inhibitor, this must be added to the solution to provide protection against corrosion and pitting.

SECTION 00 -- GENERAL -- CHAPTER 1

Refer to the chart on the right when selecting the oil grade for your tractor engine.

-30 OC

In areas where prolonged periods of extreme temperatures are encountered, local lubricant practices are acceptable; such as the use of SAE 5W in extreme low temperatures or SAE 50 in extreme high temperatures. Sulphur in Fuel Locally available fuel may have a high sulphur content, in which case the engine oil change period should be adjusted as follows: Sulphur Content %

-25 OC

-15 OC

normal

0.5 to 1.0

half the normal

above 1.0

one quarter normal

+40 OC

SAE 5W-30

SAE 10W-30

SAE 15W-40 -22 OF

-13 OF

+5 OF

+68 OF

+104 OF

Oil Change Period

less than 0.5

+20 OC

The use of fuel with a sulphur content above 1.3% is not recommended.

BIODEGRADABLE TRANSMISSION, DRIVE AXLE, HUB, AND HYDRAULIC SYSTEM OIL A biodegradable oil has been approved for use in the transmission, drive axles, hubs, and hydraulic system of your tractor. The oil is sold under the name New Holland AMBRA MULTI BIO S and it is available through your authorized dealer. While AMBRA MULTI BIO S oil is 90% biodegradable, it is still important to follow safe handling and disposal practices. AMBRA MULTI BIO S oil should not be used in conjunction with other oils. Use the following procedure to replace standard oil with AMBRA MULTI BIO S. 1. Operate tractor until the oil that is being replaced reaches a temperature greater than 60Â°C (140Â°F). 2. Stop the engine and immediately drain the oil following the instructions in this section. 3. Replace all transmission and hydraulic filters. 4. Add AMBRA MULTI BIO S to the proper level and run the tractor to circulate the oil. 5. Check for leaks and recheck the oil level. AMBRA MULTI BIO S is available in 5 gallon (PN 86994341) or 55 gallon (PN 86994342) containers.

BIODIESEL FUEL The use of biodiesel blends meeting specification standards ASTM 6751 or EN14214 is approved for your engine up to B5 (5% blend ratio). It is highly recommended that you use biodiesel fuel from accredited suppliers to maintain the quality and consistency of the fuel. Biodiesel does not have a long term stability and should not be left in engines or stored for more than four months, the engine should be flushed by running for a minimum of 30 minutes with conventional diesel fuel. Biodiesel has a higher cloud point than conventional diesel fuels and is not recommended for use in winter months. Consult your dealer for winter fuel requirements for your area. Biodiesel fuel attracts moisture and may contain a higher water content than conventional diesel fuel. It may be necessary to drain the fuel filter water trap more frequently.

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 - ENGINE Chapter 1 - Engine CONTENTS Section

Description

Page

10 001 54

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Rotating Counterweight Dynamic Balancer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Compression Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Checks, Dimensions, and Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Cylinder Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Crankshaft, Main Bearings, and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Connecting Rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66 Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Tappets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Valve Timing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Cylinder Head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

10 102 70

SECTION 10 -- ENGINE -- CHAPTER 1 SPECIFICATIONS

Engine type: - TD80D (BOSCH pump; naturally aspirated) . . . . . . . . . . . . . . . .

238 cu-in (3.0 L)

- TD95D (BOSCH pump; turbocharged) . . . . . . . . . . . . . . . . . . . .

238 cu-in (3.0 L)

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

Diesel, 4-stroke

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

Direct

No. of in-line cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dry force-fitted in cylinder block

Piston diameter: - TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 mm (4.094 in)

- TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104 mm (4.094 in)

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

115 mm

Total displacement: - TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3908 cm3 (238 in3) 3908 cm3 (238 in3)

Compression ratio: - TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17 to 1 naturally aspirated 16.5 to 1 turbocharged

Maximum power: - TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

72 hp @ 2500 rpm 90 hp @ 2500 rpm

Fast idling speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2500 rev/min

Maximum torque @ 1400 rpm: - TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

282 N⋅m (208 ft-lb) 365 N⋅m (269 ft-lb)

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

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

Structural, cast iron

Rev counter/hourmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

incorporated in control panel

Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

from gear on camshaft

Hour counter calibrated for engine speed of . . . . . . . . . . . . . . . .

1800 rpm

SECTION 10 -- ENGINE -- CHAPTER 1 Timing System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

overhead valves operated camshaft located in engine block through tappets, pushrods and rockers; camshaft is driven by the crankshaft through helical gears

Intake: --

start: before TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12o

end: after BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

31o

Exhaust: --

start: before BDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50o

end: after TDC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16o

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . .

0.45 mm (0.0177 in)

Valve clearance for normal running (engine cold): --

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

0.30 ± 0.05 mm (0.01 ± 0.002 inches)

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

0.30 ± 0.05 mm (0.01 ± 0.002 inches)

CRANKCASE/CYLINDER BLOCK DATA

mm (in)

Cylinder block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast-iron monobloc with parent-bore cylinders, incorporating seatings for crankshaft bearings, camshaft and pushrod/tappet assemblies

Internal diameter of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104.000 to 104.024 (4.094 - 4.095)

Maximum permissible cylinders ovality or taper due to wear (1) .

0.12 (0.004)

Diameter of main shell bearing seats . . . . . . . . . . . . . . . . . . . . . . . .

84.200 to 84.230 (3.314 - 3.316)

Diameter of camshaft bearing seats: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.780 to 54.805 (2.156 - 2.157)

- center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.280 to 54.305 (2.137 - 2.138)

- rear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.780 to 53.805 (2.117 - 2.118)

Diameter of standard tappet bores in crankcase . . . . . . . . . . . . . .

15.000 to15.018 (0.590 - 0 .591)

Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1 - 0.2 - 0.3 (0.004 - 0.007 - 0.011)

(1) Measure in the area swept by piston rings, both parallel and perpendicular to the crankshaft axis.

SECTION 10 -- ENGINE -- CHAPTER 1

CRANKSHAFT AND BEARINGS DATA

mm (in)

Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

balanced with integral counterweights

Standard journal diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

79.791 to 79.810 (1) (3.141 - 3.142) (1)

Journal undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 (0.01 - 0.02 - 0.03 - 0.04)

Standard main bearing shell thickness . . . . . . . . . . . . . . . . . . . . . . .

2.168 to 2.178 (0.085 - 0.086)

Main bearing shell undersizes (internal diameter) . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 (0.01 - 0.02 - 0.03 - 0.04)

Bearing shell to journal clearance . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.034 to 0.103 (0.001 - 0.004)

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

0.180 (0.007)

Standard crankpin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63.725 to 63.744 (1) (2.508 - 2.510) (1)

Crankpin undersizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 (0.01 - 0.02 - 0.03 - 0.04)

Standard big-end bearing shell thickness . . . . . . . . . . . . . . . . . . . .

1.805 to 1.815 (0.0710 - 0.0714)

Big-end bearing shell undersizes (internal diameter) . . . . . . . . . . .

0.254 - 0.508 - 0.762 - 1.016 (0.01 - 0.02 - 0.03 - 0.04)

Big-end bearing shell to crankpin clearance . . . . . . . . . . . . . . . . . .

0.033 to 0.087 (0.001 - 0.003)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.180 (0.007)

Standard crankshaft thrust washer thickness . . . . . . . . . . . . . . . . .

3.378 to 3.429 (0.132 - 0 .135)

Thrust washer oversizes (thickness) . . . . . . . . . . . . . . . . . . . . . . . .

0.127 - 0.254 - 0.381 - 0.508 (0.005 - 0.01 - 0.015 - 0.02)

Width of main bearing including thrust washers . . . . . . . . . . . . . . .

31.766 to 31.918 (1.250 - 1.256)

Width of corresponding crankshaft journal . . . . . . . . . . . . . . . . . . . .

32.000 to 32.100 (1.259 - 1.263)

Crankshaft assembly endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.082 to 0.334 (0.003 - 0.013)

Maximum permitted wear endfloat . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 (0.015)

Maximum ovality or taper of worn journals and crankpin after regrinding . . . .

0.01 (0.0004)

Maximum ovality or taper of journals and crankpin . . . . . . . . . . . .

0.05 (0.002)

Maximum tolerance for alignment of crankshaft journals with crankshaft supported on the two outer journals . . . . . . . . . . . . . . .

0.10 (0.004)

Maximum tolerance for alignment, in both directions, of crankpins (3 cylinder engines) or each pair of crankpins (4 cylinder engines) relative to crankshaft journals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum tolerance for runout between the outer surfaces of the crankshaft journals and the crankshaft centerline . . . . . . . . . . . . . .

0.25 (0.010)

Âą 0.10 (0.004) (continued)

(1) Crankshafts with 0.1 mm (0.004 in) undersize journals, crankpins and, consequently, undersize bearing shells may be installed in factory production.

SECTION 10 -- ENGINE -- CHAPTER 1 CRANKSHAFT AND BEARINGS DATA

mm (in)

Maximum permitted tolerance on runout of flywheel mounting flange surface relative to the crankshaft centerline, measured with 1/100 mm scale dial gauge resting on front flange surface at a diameter of 108 mm (4.25 in) (total gauge reading) . . . . . . . . . . . . . .

0.025 (0.001)

Maximum permitted tolerance on coaxial alignment of flywheel centering relative to the crankshaft journals (total gauge reading) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.04 (0.0015)

CONNECTING ROD DATA

mm (in)

Connecting rods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

cast iron with oilway

Diameter of small end bushing seat . . . . . . . . . . . . . . . . . . . . . . . . .

41.846 to 41.884 (1.647 - 1.648)

Outside diameter of small end bushing . . . . . . . . . . . . . . . . . . . . . .

41.979 to 42.017 (1.652 - 1.654)

Interference between small end bushing and seat . . . . . . . . . . . .

0.095 to 0.171 (0.003 - 0.006)

Inside diameter of small end bushing (measured after installing) . .

38.004 to 38.014 (1.4962 - 1.4966)

Diameter of big end bearing seats . . . . . . . . . . . . . . . . . . . . . . . . . .

67.407 to 67.422 (2.653 - 2.655)

Max. tolerance for parallelism between the small end and the big end axes measured at 25 mm (0.9843 in) . . . . . . . . . . . . . . . . . . . .

Âą 0.07 (Âą 0.002)

Maximum weight difference between con rods in same engine . .

25 grams (0.881 oz)

SECTION 10 -- ENGINE -- CHAPTER 1

PISTON DATA

mm (in)

Pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . light alloy with two compression rings and one oil control ring Standard piston diameter, measured at 57 mm (2.24 in) from skirt base and perpendicularly to the gudgeon pin axis . . . . . . . . Piston clearance in cylinder liners . . . . . . . . . . . . . . . . . . . . . . . . . .

103.812 to 103.826 (4.087 - 4.088) 0.174 to 0.212 (0.007 - 0.008) 103 812 to 103.826 103.812 103 826 (4.087 (4 087 - 4.088) 4 088) 0.174 to 0.212 (0.007 - 0.008)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 (0.011)

Piston oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.4 - 0.6-0.8 (0.015-0.0236 - 0.031)

Piston protrusion at TDC from cylinder block face . . . . . . . . . . . .

0.355 to 0.761 (0.014 - 0.029)

Gudgeon pin diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.983 to 37.990 (1.4953 - 1.4956)

Diameter of gudgeon pin seat in piston . . . . . . . . . . . . . . . . . . . . .

37.993 to 38.000 (1.4957 - 1.4960)

Gudgeon pin to seat clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.004 to 0.017 (0.0001 - 0.0006)

Gudgeon pin to small end bearing clearance . . . . . . . . . . . . . . . .

0.014 to 0.031 (0.0005 - 0.001)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.06 (0.002)

Maximum weight difference between pistons in same engine . .

20 grams (0.705 oz)

Piston ring groove clearance (measured vertically): . . . . . . . . . . . - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.105 to 0.155 (0.0041 - 0.0061)

- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.060 to 0.092 (0.002 - 0.003)

- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.040 to 0.075 (0.0015 - 0.003)

Max. permissible clearance (wear limit): - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.50 (0.019)

- Second and bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 (0.007)

Piston ring end gap (installed): - Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.40 to 0.65 (0.015 - 0.025)

- Second . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.55 (0.011 - 0.021)

- Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 to 0.55 (0.0118 - 0.0217)

Maximum permissible gap (wear limit) . . . . . . . . . . . . . . . . . . . . . .

1.20 (0.047)

SECTION 10 -- ENGINE -- CHAPTER 1 VALVE TIMING GEAR DATA

mm (in)

Timing gear tooth backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.160 (0.006)

Inside diameter of intermediate gear bushings (installed and reamed) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.050 to 37.075 (1.458 - 1.459)

Diameter of intermediate gear journal . . . . . . . . . . . . . . . . . . . . . . .

36.975 to 37.000 (1.455 - 1.456)

Journal to bushing clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.002 - 0.004)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 (0.006)

Bushing interference fit in seat in intermediate gear . . . . . . . . . . . .

0.063 to 0.140 (0.002 - 0.005)

Outside diameter of camshaft bearings: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.875 to 54.930 (2.160 - 2.162)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

54.375 to 54.430 (2.140 - 2.142)

- drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53.875 to 53.930 (2.121 - 2.123)

Interference between bearings and seats in cylinder block . . . . . .

0.070 to 0.150 (0.002 - 0.006)

Inside diameter of camshaft bearings (installed and reamed): - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51.080 to 51.130 (2.011 - 2.013)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.580 to 50.630 (1.991 - 1.993)

- drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.080 to 50.130 (2.011 - 2.013)

Diameter of camshaft journals: - front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.970 to 51.000 (2.006 - 2.008)

- intermediate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

50.470 to 50.500 (1.987 - 1.988)

- drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

49.970 to 50.000 (1.967 - 1.968)

Clearance between camshaft journals and bearings . . . . . . . . . . .

0.080 to 0.160 (0.003 - 0.006)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.20 (0.008)

Camshaft endfloat between thrust plate and seat on camshaft . .

0.070 to 0.220 (0.002 - 0.008)

TAPPET DATA

mm (in)

Tappet bore in crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.000 to 15.018 (0.590 - 0.591)

Outside diameter of standard tappet . . . . . . . . . . . . . . . . . . . . . . . . .

14.950 to 14.970 (0.588 - 0.589)

Tappet running clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.030 to 0.068 (0.001 - 0.002)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 (0.006)

Tappet oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.1 - 0.2 - 0.3 (0.004 - 0.008 - 0.012)

SECTION 10 -- ENGINE -- CHAPTER 1

ROCKER ARM - VALVE DATA

mm (in)

Diameter of shaft bores in rocker arms . . . . . . . . . . . . . . . . . . . . . .

18.016 to 18.034 (0.709 - 0.710)

Diameter of rocker arm shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.982 to 18.000 (0.707 - 0.708)

Rocker shaft to rocker arm bore clearance . . . . . . . . . . . . . . . . . . .

0.016 to 0.052 (0.0006 - 0.002)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.15 (0.006)

Rocker arm spacing springs: - free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

59.5 (2.342)

- length under load of 46 to 52 N (10.3 to 11.6 lbs) . . . . . . . . . . . . .

44 (1.732)

Valve clearance for timing check . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.45 (0.017)

Valve clearance for normal running (engine cold): - intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 ± 0.05 (0.012 ± 0.002)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.30 ± 0.05 (0.012 ± 0.002)

Cam lift: - intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5.97 (0.235)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6.25 (0.246)

ROTATING COUNTERWEIGHT DYNAMIC BALANCER DATA

mm (in)

Interference fit between bushings and intermediate gear . . . . . . .

0.063 to 0.140 (0.002 - 0.005)

Clearance between intermediate gear journal and bushings . . . . . . .

0.050 to 0.100 (0.002 - 0.004)

Interference fit between bushings and carrier . . . . . . . . . . . . . . . . .

0.063 to 0.140 (0.002 - 0.005)

Clearance between gear shaft and bushings . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.002 - 0.004)

Tooth backlash between coupling sleeve, connecting drive box gear and counterweight drive gear . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.038 to 0.106 (0.001 - 0.004)

Interference fit between front bushing and bore in housing . . . . . . . . .

0.063 to 0.140 (0.002 - 0.005)

Clearance between counterweight drive gear and front bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.050 to 0.100 (0.002 - 0.004)

Interference fit between rear bushing of counterweight drive gear and seat in carrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 (0.001 - 0.004)

Clearance between counterweight drive shaft and rear bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.013 to 0.061 (0.0005 - 0.002)

Interference fit between bushing and seat in counterweight . . . . .

0.040 to 0.100 (0.0015 - 0.004)

Clearance between counterweight rotation shaft and bushing . . .

0.020 to 0.073 (0.0007 - 0.0028)

Interference fit between intermediate gear bushing and relative seat in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.037 to 0.101 (0.001 - 0.004)

Clearance between intermediate gear shaft and relative bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.013 to 0.061 (0.0005 - 0.002)

Tooth backlash between meshed gears . . . . . . . . . . . . . . . . . . . . . .

0.080 (0.003)

SECTION 10 -- ENGINE -- CHAPTER 1 CYLINDER HEAD DATA

mm (in)

Cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with valve seats cut directly in the casting and press-fitted steel valve guides.

Original height of cylinder head . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

92 (3.622)

Maximum face regrinding depth . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.5 (0.019)

Diameter of standard valve guide bores in head . . . . . . . . . . . . . . .

13.950 to 13.983 (0.549 - 0.550)

Outside diameter of standard valve guides . . . . . . . . . . . . . . . . . . .

13.993 to 14.016 (0.550 - 0.551)

Guide interference fit in bores . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.010 to 0.066 (0.0004 - 0.002)

Inside diameter of valve guide (installed in head) . . . . . . . . . . . . . .

8.023 to 8.043 (0.315 - 0.316)

Valve stem diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7. 985 to 8.000 (0.314 - 0.315)

Assembly clearance between valve stem and guide . . . . . . . . . . .

0.023 to 0.058 (0.001 - 0.002)

Wear limit endfloat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.13 (0.005)

Maximum runout of valve guided on its stem measured through 360û with dial gauge contact point resting on valve head contact band . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.03 (0.001)

Valve guide oversizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.2 (0.007)

Valve seat angle in head: - intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60o ± 5′

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45o ± 5′

Valve face angle: - intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

60o 30′ ± 7′

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45o 30′ ± 7′

Valve head diameter: - intake valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45.300 to 45.500 (1.783 - 1.791)

- exhaust valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

37.500 to 37.750 (1.476 - 1.486)

Valve stand-in relative to cylinder head face . . . . . . . . . . . . . . . . . .

0.7 to 1.0 (0.027 - 0.039)

Maximum permissible valve stand-in . . . . . . . . . . . . . . . . . . . . . . . .

1.3 (0.051)

Intake and exhaust valve springs: - free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

44.6 (1.755)

- length with valve closed, under load of 256 to 284 N (57.55 to 63.71 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34 (1.338)

- length with valve open, under load of 502 to 554 N (112.8 to 124.78 lbs) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23.8 (0.937)

Injector protrusion relative to head face: D

BOSCH injector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 to 1.1 (0.011 - 0.043)

SECTION 10 -- ENGINE -- CHAPTER 1 SPECIAL TOOLS

WARNING

380000222

Engine valve guide reamer.

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.

380000302

Engine valve spring disassemblyassembly compressor.

380000246

Set of grinding tools for regrinding injector seat.

380000223

Puller for coolant pump impeller.

380000247

Drift for installation of coolant pump impeller seal.

380000215

Calibration hand pump.

380000311

Wrench for injection pump delivery line unions.

List of specific tools required for the various operations described in this Section. 380000236

Tractor dismantling stand.

380000254

Injector cleaning kit.

380000216

Engine lifting hook.

380000308

Injector splitting support.

380000301

Revolving engine service stand.

380000309

380000313

Engine mounting brackets for rotating stand 380000301.

Wrench set for injector dismantling.

380000310

380000303

Compression test kit (complete with dummy injector 380000617).

Hand pump for injector calibration test.

380001613

Engine/Axle bracket.

380000549

Slide hammer.

380000240

Engine oil lubrication pressure test kit.

380000221

Piston ring pliers.

380000220

Clamp for installing pistons in cylinders.

380000304

Protractor for angular torque measurement.

380000226

Puller for crankshaft pulley hub.

380000232

Wrench for valve clearance adjustment.

380000219

Punch for valve guide extraction / installation.

380000276

Twist bit for enlarging valve guide bore.

380000277

Injection pump bench test X 380000228(1) Dial gauge (1/100 mm, 0.1968 in (5 mm) stroke, â&#x2C6;&#x2026; 1.5748 in (40 mm) with 380001601). X 380001601(2) Device for BOSCH injection pump timing on engine (with 380000228). X 380000322

Puller for injection pump drive gear.

380000259

Compressor impeller reaction block.

380000829

(M12 x 1.74) Tap.

Tapered grinder for enlarging 8Â° exhaust valve guides.

380000832

Fuel injector sleeve retractor.

380000834

Dressing tool.

380000328

Drive belt tension device.

380000370

Deburr tool.

380000242

Bush for valve guide installation (with 380000219).

(1) The current gauge 380000228 for timing BOSCH fuel injection pumps consists of a larger dial indicating face than older versions with the same part number. Special tool 380001601 accommodates both type gauges. (2) The special tool for timing BOSCH fuel injection pumps with part number 380001601 will include the following: 1. Stem, indicator (.5 in) [installs into Dial Gauge 380000228] 2. Pin, stainless steel (1.75 in) [installed with current style Dial Gauge 380000228] 3. Pin, stainless steel (2 in) [installed with older version of Dial Gauge 380000228] 4. Adapter, timing [installed into the fuel injection pump and secures Dial Gauge 380000228 in position]

SECTION 10 -- ENGINE -- CHAPTER 1

Tool part number 380001601 for timing Bosch Fuel Injection Pump

50044227

SECTION 10 -- ENGINE -- CHAPTER 1

Mounting for engine lifting hook (No. 50075 - measurements in mm). Make with UNI C40.

26101

2 Splining tool to be manufactured for assembling the crankshaft front seal (print on the tool no. 50138 - values in mm). Material UNI C40.

26102

3 Splining tool to be manufactured for assembling the crankshaft rear seal (print on the tool no. 50139 - values in mm). Material UNI C40.

26103

SECTION 10 -- ENGINE -- CHAPTER 1

26104

Rear mountings for lifting hood (No. 50131 - measurements in mm). Make with UNI Fe 42C - Quantity = 2.

Front hook for lifting hood (50132 - Measurements in mm). Make with UNI C40.

26105

SECTION 10 -- ENGINE -- CHAPTER 1 TIGHTENING TORQUES

ANGULAR TORQUE DATA PART (Refer to Figure 7)

Thread size

Preliminary torque N⋅m

ft-lb

Angle

Cylinder head bolts (1) . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

90o + 90o

Main bearing cap bolts (2) . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

90o

Big-end cap bolts (3) . . . . . . . . . . . . . . . . . . . . . . . .

M 11 x 1.5

60o

Flywheel mounting bolts (4) . . . . . . . . . . . . . . . . . .

M 12 x 1.25

60o

Rocker shaft pedestal bolts (5) . . . . . . . . . . . . . . .

Crankshaft hub retaining nut (6) . . . . . . . . . . . . . .

M 30 x 1.5

294

216

Fan and alternator pulley bolts (7) . . . . . . . . . . . . .

M 10 x 1.25

Additional counterweight retaining bolts . . . . . . . .

M 12 x 1.25

110

Inlet manifold retaining bolts . . . . . . . . . . . . . . . . . .

Alternator and belt tension adjustment nut . . . . . .

M 10 x 1.25

Coolant pump retaining bolts . . . . . . . . . . . . . . . . .

M 10 x 1.25

Rocker cover nuts . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker shaft pedestal bolts . . . . . . . . . . . . . . . . . .

Oil pump and pump cover retaining bolts . . . . . . .

Timing gear case and cover bolts . . . . . . . . . . . . .

Intermediate flanged journal bolts . . . . . . . . . . . .

M 10 x 1.25

Camshaft thrust plate retaining bolts . . . . . . . . . .

Rear crankcase cover bolts . . . . . . . . . . . . . . . . . .

Tappet adjuster screw locknuts . . . . . . . . . . . . . . .

Nuts for injector mounting studs . . . . . . . . . . . . . .

Exhaust manifold retaining bolts . . . . . . . . . . . . . .

Injection pump mounting bolts . . . . . . . . . . . . . . . .

M 10 X 1.25

39 - 49

28 - 36

M 10 X 1.25 M 10 X 1.25

49 - 59 49 - 69

36 - 43 36 - 51

Sump pan retaining bolts to - inner rear timing cover and gear case . . . . . . . . - cylinder block and flywheel case • Model TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . • Model TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 10 -- ENGINE -- CHAPTER 1 SECTIONAL VIEWS

5 1

25357

7 1. 2. 3. 4.

Cylinder Head Bolts Main Bearing Cap Bolts Big-end Cap Bolts Flywheel Mounting Bolts

Longitudinal View of Engine 5. 6. 7.

Rocker Shaft Pedestal Bolts Crankshaft Hub Retaining Nut Fan and Alternator Pulley Bolts

SECTION 10 -- ENGINE -- CHAPTER 1

1 25358

Cross-section View of Engine 1.

Counterweight retaining bolts

SECTION 10 -- ENGINE -- CHAPTER 1 TROUBLESHOOTING Problem Engine does not start.

Engine stalls.

Possible Cause

Remedy

Battery partially discharged.

Check and recharge battery. Replace if necessary.

Battery terminal connections corroded or loose.

Clean, inspect and tighten terminal nuts. Replace terminals and nuts if excessively corroded.

Injection pump timing incorrect.

Adjust injection pump timing.

Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

No fuel in tank.

Fill tank.

Fuel supply pump malfunction.

Check and replace pump if necessary.

Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system.

Starter motor faulty.

Repair or replace starter motor.

Thermostarter faulty.

Check and replace thermostarter if necessary.

Idle speed too low.

Adjust idle speed.

Irregular delivery from injection pump.

Check injection pump delivery on test bench.

Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank.

Fuel filters clogged.

Replace filter cartridges.

Incorrect valve clearances.

Adjust valve clearances.

Burnt or cracked valves.

Replace valves.

Air in fuel system.

Check fuel lines, unions, supply pump, filters and injection pump for air, then bleed system.

Injection pump drive mechanism damaged.

Replace damaged parts. (continued)

SECTION 10 -- ENGINE -- CHAPTER 1 TROUBLESHOOTING Problem

Engine overheats.

Possible Cause

Remedy

Coolant pump malfunction.

Overhaul pump or replace.

Thermostat faulty.

Replace thermostat.

Radiator inefficient.

Remove internal deposits by flushing. Check for leaks and repair.

Deposits in cylinder head and crank- Flush out coolant system. case coolant passages. Coolant pump and fan drive belt slack.

Check and adjust belt tension.

Coolant level low.

Top up expansion tank with specified coolant mixture.

Incorrect timing.

Check and adjust.

Injection pump calibration incorrect delivering too much or too little fuel.

Calibrate pump on test bench to values specified in Chapter 4, this section.

Air filter clogged.

Clean filter unit and replace filter element if necessary.

Engine lacks power and runs Injection pump timing incorrect. unevenly.

Adjust pump timing.

Auto advance regulator in injection pump damaged.

Overhaul injection pump and adjust on test bench to values specified in Chapter 4, this section.

Distributor journal worn.

Overhaul injection pump and adjust on test bench to values specified in Chapter 4, this section.

Injection pump delivery irregular.

Overhaul injection pump and adjust on test bench to values specified in Chapter 4, this section.

All-speed governor damaged.

Overhaul injection pump and adjust on test bench to values specified in Chapter 4, this section.

Injectors partially obstructed or dam- Clean, overhaul and calibrate injectors. aged. Impurities or water in fuel lines.

Disconnect fuel lines from injection pump and clean thoroughly. If necessary clean and dry the fuel tank. (continued)

SECTION 10 -- ENGINE -- CHAPTER 1 TROUBLESHOOTING Problem

Possible Cause

Engine lacks power and runs Fuel supply pump damaged. unevenly. (continued)

Engine produces knocking noises.

Remedy Replace fuel supply pump.

Incorrect valve clearances.

Adjust valve clearances.

Cylinder compression low.

Test compression and overhaul engine if necessary.

Air filter clogged.

Clean air filter unit and replace element if necessary.

Tierod in linkage between accelerator and injection pump incorrectly adjusted.

Adjust to correct length.

Maximum speed screw on injection pump incorrectly adjusted.

Adjust max. speed screw.

abnormal Injectors partially obstructed or dam- Clean, overhaul and calibrate injectors. aged. Impurities accumulating in fuel lines.

Clean fuel lines and replace severely dented pipes. Clean injection pump if necessary.

Incorrect injection pump timing.

Adjust injection pump timing.

Crankshaft knocking due to excessive play in one or more main or big-end bearings or excessive endfloat.

Regrind crankshaft journals and crankpins. Install oversize shell bearings and thrust washers.

Crankshaft unbalanced.

Check crankshaft alignment and balance; replace if necessary.

Flywheel bolts loose.

Replace any bolts that have worked loose and tighten all bolts to the specified preliminary and angular torque values.

Connecting rod axes not parallel.

Straighten connecting rods, check axes parallelism; replace connecting rods if necessary.

Piston knock due to excessive wear. Rebore cylinders and install oversize pistons. Noise caused by excessive play of gudgeon pins in small-end and piston bushings, or loose fit of small-end bushing.

Install oversize gudgeon pin, rebore piston seats and small-end bushings. Replace bushings.

Excessive tappet / valve noise.

Check for broken springs or excessive play between valve stems and guides, cam followers and bores. Adjust valve clearances. (continued)

SECTION 10 -- ENGINE -- CHAPTER 1 TROUBLESHOOTING Problem

Possible Cause

Engine produces excessive Maximum delivery of injection pump black or dark gray smoke. too high.

Remedy Adjust injection pump on test bench to the values specified in Chapter 4, this section.

Injection pump delivery excessively retarded or automatic advance regulator damaged.

Adjust injection pump / engine timing or check automatic advance regulator.

Injection pump delivery excessively advanced.

Adjust injection pump / engine timing.

Injectors partially or totally obstructed or incorrectly adjusted.

Clean and overhaul injectors and adjust pressure setting; replace if necessary.

Air filter clogged.

Clean air filter unit and replace element if necessary.

Loss of engine compression due to: Replace damaged parts or, if necessary, recondition engine. -- piston rings sticking; -- cylinder wear; -- worn or incorrectly adjusted valves. Damaged high-pressure fuel lines.

Inspect and replace if necessary.

Blue, gray-blue or gray-white Injection pump delivery excessively Adjust injection pump / engine tismoke. retarded or automatic advance regu- ming or check automatic advance regulator. lator damaged.

Engine runs on after switching off.

Injectors obstructed or damaged.

Clean and overhaul injectors and adjust pressure setting; replace if necessary.

Oil leaking past piston rings due to sticking rings or cylinder wear.

Replace damaged parts or, if necessary, recondition engine.

Oil leaking through the intake valve guides due to guide or valve stem wear.

Recondition cylinder head.

Engine does not reach correct operating temperature (thermostat faulty).

Replace thermostat.

Engine stop solenoid damaged.

Replace solenoid.

All-speed governor damaged.

Recondition injection pump and adjust on test bench to values specified in Chapter 4, this section.

SECTION 10 -- ENGINE -- CHAPTER 1 OVERHAUL ENGINE Removal

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. Make sure that no-one is standing in the vicinity of the load to be lifted.

WARNING

Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS.

1. Disconnect the battery negative (ground) and positive cables (1). 2. Drain oil from the transmission/gearbox. 3. Drain the cooling system.

25621

9 4. Unscrew the nut (1) from the front ballast retaining pin.

TRE0601A

22 5.

SECTION 10 -- ENGINE -- CHAPTER 1 Remove the ballast (1) from the front support.

TRE0602A

11 6. Remove the exhaust pipe. Attach lifting chains to the hood (1) using tools 50131 and 50132 and attach the chain to the hoist.

24872

12 7. Detach the electrical leads (1) from the headlamps (2).

1 2

24873

13 8. Detach the struts (1) from hood.

TRE0603A

SECTION 10 -- ENGINE -- CHAPTER 1 9. Remove the four hood hinge bolts (1) and lift the hood clear.

TRE0604A

15 10. Remove the fan guard (1) from right-hand side of the fan.

25028

11. Disconnect the tachometer cable (1) and remove the retaining ring and sleeve.

25046

17 12. Detach the throttle control spring (1) and remove the throttle lever (2).

25183

SECTION 10 -- ENGINE -- CHAPTER 1

13. Detach the cab air-conditioning pipes (1) and (2) (if applicable).

2 24892

19 14. Detach the cab heating pipes (1) and (2) (if applicable).

25411

20 15. Disconnect connectors.

the

main

harness

electrical

TRE0605A

21 16. Remove the fusebox by unscrewing the nut (1).

TRE0606A

SECTION 10 -- ENGINE -- CHAPTER 1 17. Disconnect the delivery and return lines (1) to the power steering cylinders.

TRE0607A

23 18. Remove the supply hose (1) from the lift pump.

1 TRE0608A

24 19. Detach the lift pump delivery pipe (1).

1 TRE0609A

25 20. Detach the fuel pipes from the fuel injection pump and the pipe connecting the fuel tank to the fuel filter (1).

TRE0610A

SECTION 10 -- ENGINE -- CHAPTER 1

21. Remove the fuel filter (1) and support.

25035

27 22. Remove the front, center and rear retaining bolts from the front axle drive shaft guard and remove the guard (models with FWD).

25038

28 23. Remove the circlip (2) from the front of the drive shaft and slide the sleeve (1), in the direction shown by the arrow (see figure), until it is free of the splines on the front axle (models with FWD).

25039

29 24. Remove the circlip (2) from the rear of the drive shaft and slide the sleeve (1), in the direction shown by the arrow (see figure), until it is free of the spines on the drive shaft (models with FWD).

2 25040

SECTION 10 -- ENGINE -- CHAPTER 1 25. Remove the retaining bolts from the central drive shaft support (1) and remove the shaft complete with support (models with FWD).

1 25041

31 26. Withdraw the pin securing the differential lock knob (1), remove the knob and remove the mat from the floor. 1

TRE0611A

32 27. Unscrew the nuts (1) and the bolts securing the engine to the transmission. Access is through the two slots in the cab floor.

11 TRE0612A

33 28. Unscrew the four lower bolts (1) securing the engine to the transmission.

1 25049

SECTION 10 -- ENGINE -- CHAPTER 1

29. Position stand 380000236 underneath the tractor and insert a wedge (1), either side of the axle, to prevent the axle from pivoting.

25050

35 30. Insert a wooden block between the stands and the tractor.

25051

36 31. Place a fixed stand (1) underneath the drawbar support and apply the handbrake.

1 25052

32. Unscrew the four remaining bolts securing the engine to the transmission. 33. Separate the engine from the transmission. 34. Remove the distance collar (1) between the engine and transmission.

25055

SECTION 10 -- ENGINE -- CHAPTER 1 35. Place a fixed stand (1) underneath the front ballast support and chock the wheels with wooden wedges (2).

25056

2 39

36. Insert tool 380000292 (1) in the clutch center hole. Unscrew the six bolts (2) securing the clutch to the flywheel and remove complete clutch assembly.

25057

2 40

37. Remove the radiator support bracket (1).

TRE0613A

41 38. Attach the engine to the hoist using an adjustable chain (1) attached to the lifting points provided on the engine.

25060

SECTION 10 -- ENGINE -- CHAPTER 1

39. Remove the lift pump (1) complete with the filter by unscrewing the four retaining bolts.

1 TRE0614A

43 40. Disconnect all electrical connectors and remove the complete wiring harness (1).

1 TRE0615A

44 41. Loosen of the hose clamp and detach hose (1) from the inlet manifold.

TRE0616A

45 42. Remove the left-hand side fan guard (1).

TRE0617A

SECTION 10 -- ENGINE -- CHAPTER 1 43. Unscrew the bolts (1) securing the muffler to the bracket. 44. Unscrew the three nuts securing the muffler (2) to the manifold and lift off the entire muffler assembly.

2 1

TRE0618A

47 45. Remove the hose clamp and disconnect the top radiator hose (1).

TRE0619A

48 46. Using the hoist, raise the engine slightly and position the moveable stand (1) under the front axle.

1 25068

49 47. Remove the hose clamp and disconnect the bottom radiator hose (1). 48. Unscrew the four bolts (2) securing the engine to the front axle support, and lower the engine onto a wooden platform.

25069

SECTION 10 -- ENGINE -- CHAPTER 1

Installation To install the engine, proceed as follows: 1. Attach the three hooks of an adjustable lifting chain to three eye bolts on the engine. Raise the engine from the platform and position it in front of the front axle support. Join the two units using the four securing bolts. 2. Move the mobile stand from under the front axle differential housing to under the engine sump, inserting a suitably shaped block of wood between the stand and the sump pan. 3. Attach the top radiator hose to the thermostat housing and secure with an adjustable hose clamp. 4. Connect the bottom radiator hose to the coolant pump and secure at both ends with adjustable hose clamps. 5. Install the lift pump. 6. Detach the lifting chain from the engine. 7. Connect the rigid pipe from the air cleaner to the inlet manifold and secure with the relative clamp. 8. Reconnect all electrical leads: thermostart glow plug, coolant temperature sensor, â&#x20AC;&#x2DC;air filter blockedâ&#x20AC;&#x2122; sensor, horn, front axle support ground, engine stop on injection pump, leads to the alternator and relay, oil pressure sensor, starter motor, fuel dryer filter. Secure all leads with plastic ties. 9. Install the clutch to the engine flywheel using the six retaining bolts. 10. Connect the oil delivery pipe to the DT control valve. Tighten the pipe union on the anti-cavitation accumulator; install the bracket on the left-hand side near the engine oil filter. 11. Clean the distance collar and the mating surfaces of the overdrive clutch housing; scrape away all traces of old sealing compound. 12. Apply silicone sealing compound to the mating surfaces of engine and distance collar. Install the distance ring on the engine studs.

13. Apply silicone sealing compound to the mating surfaces of the overdrive clutch housing. 14. Remove the fixed stand from under the front weight support. Remove the wooden wedges from under the front wheels. 15. Attach the adjustable lifting chain to the eyebolts on the engine. 16. Place wooden wedges under the rear wheels, check that the handbrake is fully on and that the fixed and moveable stands are firmly in place. 17. Detach the lifting chain from the engine. Attach the two cables still attached to the cab handrail to the hook of the hoist. Raise the front part of the cab about 6 cm. (2.36 in). 18. Replace and tighten all the bolts securing the engine to the overdrive clutch housing. 19. Bolt on the brake pipe support bracket on the right-hand side of the engine. Lower the hoist and detach the cables from the cab handrail. 20. Lower the stands under the engine sump and the clutch housing. Remove tool 380000236 and the stand from under the drawbar support. 21. Fix the cab in place with the two front securing bolts. 22. Connect the injector leak-off pipe. Connect the pipes to the glowplug and to the fuel dryer filter. 23. Install the fuel filter mounting to the engine. Connect the two semirigid pipes to the mounting. 24. Connect the oil suction pipes to the pumps; secure the rubber hoses with hose clamps. 25. Connect the lift control valve supply pipe to the lift pump with a new O-ring. 26. Secure the three pipes with the adjustable hose clamp. 27. Attach all the electrical leads to the connectors on the vertical support bracket. 28. Install the cab heater pipe union on the engine/ clutch distance collar. Connect the rubber heater hoses to the union.

SECTION 10 -- ENGINE -- CHAPTER 1 29. Connect the two flexible power steering pipes to the union on the left-hand side of the front axle. Secure the two pipes with a special clamp and fix the clamp to the tractor with a screw. 30. Install the tachometer cable and secure the sleeve with the retaining ring. 31. Install the muffler onto the exhaust manifold with a new gas seal. Fix the front of the muffler to the vertical support bracket. Attach the flexible Donaspin pipe.

38. Replace the fan guards. 39. Attach slings to the hood in the manner described previously in the engine removal instructions. Screw the hood hinge to its bracket. Attach the gas strut, the electrical leads to the headlamps, and then remove the slings. 40. Install the secondary bracket (battery support) to the overdrive clutch housing. Install the rotating bracket with the battery on the fixed support.

32. Attach the support bracket to the radiator.

41. Install the front ballast and secure with the lock pin.

33. Install the FWD transmission shaft and the guard.

42. Install the tool box support bracket and then the tool box.

34. Connect the throttle cable to the accelerator pedal. It may be necessary to adjust the cable at the injection pump lever end.

43. Fill the transmission/gearbox with oil (refer to Section 00).

35. Install the clutch cable to the clutch pedal. Fix the sleeve to the travel stop. 36. Replace the plastic plugs in the holes in the cab floor. Replace the mat. 37. Install the steering column cover panels.

44. Fill the radiator with coolant mixture (refer to Section 00). 45. Connect the positive and negative battery leads. Install the plastic battery cover.

SECTION 10 -- ENGINE -- CHAPTER 1

Disassembly

1 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 front and rear retaining screws from the hood stay bracket (1).

25070

51 2. Remove the hood catch support side retaining bolts (1) and rear retaining bolts (2). Remove the hood catch and stay bracket.

1 2

25071

52 3. Loosen the alternator pivot bolt. 4. Loosen the belt tension adjustment bolt (1). 5. Release the belt tension adjustment arm by unscrewing the retaining nut. 6. Remove the alternator and coolant pump drive belt.

25072

53 7. Unscrew the bolts securing the fan (1) and pulley to the coolant pump. Remove the fan and pulley.

1 25073

SECTION 10 -- ENGINE -- CHAPTER 1

8. Unscrew the union (1) from the water supply pipe to the cab heater.

25074

55 9. Loosen the hose clamp (1) and detach the hose from the coolant pump. Remove the curved hose and flexible cab heater hoses.

25075

56 10. Remove the union (1) in order to gain access to the pump retaining bolt.

25077

57 11. Unscrew the coolant pump retaining bolts (1) and remove the pump.

25076

SECTION 10 -- ENGINE -- CHAPTER 1

12. Unscrew the pump support bolts (1) and the muffler support bolt. Remove the two supports.

25078

59 13. Install mounting bracket (1) of the set 380000313 to permit attachment of the engine to the rotary stand 380000301.

1 25079

60 14. Install an eyebolt (1) on the front of the engine in place of the muffler support. 15. Raise the engine from the wooden platform and secure it to rotary stand 380000301 (2) by means of the bracket (3) from the set 380000313.

3 2 25080

61 16. Remove the alternator support retaining bolts (1) and remove the complete alternator assembly.

25081

1 62

SECTION 10 -- ENGINE -- CHAPTER 1 17. Unscrew the bolts (1) securing the exhaust manifold to the cylinder head and remove the manifold.

25082

63 18. Detach the throttle control lever (1) from the injection pump.

25083

64 19. Remove the thermostat housing retaining bolts (1) and remove the thermostat housing.

25084

65 20. Unscrew the high pressure fuel line unions (1) on the injection pump and remove the fuel lines.

25085

SECTION 10 -- ENGINE -- CHAPTER 1

21. Unscrew the bolts (1) securing the inlet manifold to the cylinder head and remove the manifold.

25086

67 22. Remove the pipes and unions (1) to the fuel supply pump.

25087

68 23. Unscrew the nuts (1) securing the injection pump to the timing gear case.

25088

69 24. Remove bolts (1) and the injection pump drive gear cover.

25089

SECTION 10 -- ENGINE -- CHAPTER 1 25. Unscrew the nut (1) securing the injection pump shaft to the drive gear.

25090

71 26. Remove the injection pump drive gear using tool 380000835 (1) and remove the injection pump and the woodruff key. NOTE: See â&#x20AC;&#x153;Injection Pumpâ&#x20AC;? removal in Chapter 4 prior to removing fuel injector pump. Fuel injector pump must be lock timed prior to removing from the engine.

25091

72 27. Remove the fuel line unions (1) on the fuel filter.

25092

73 28. Unscrew the bolts securing the fuel filter support to the engine block and remove the complete filter assembly.

25093

SECTION 10 -- ENGINE -- CHAPTER 1

29. Unscrew the retaining nut (1) and remove the fuel pump support complete with the pump. Retain the gasket for reuse, if undamaged.

1 25094

75 30. Unscrew the power steering pump retaining bolts (1) and remove the pump complete with filter and accumulator on the delivery line.

1 25095

76 31. Remove spacer (3), gasket (2) and the pump drive connector (1).

1 2

25096

77 32. Unscrew the starter motor retaining bolts (1) and remove starter motor.

25097

SECTION 10 -- ENGINE -- CHAPTER 1 33. Remove the injector mounting nuts and the spherical washers beneath, then the supports and the injectors themselves. 34. Remove the rocker cover bolts (1), washers and seals and then the rocker cover and its gasket.

2 25098

79 35. Remove the rocker shaft retaining bolts (2), then remove the entire rocker shaft assembly (1).

25099

80 36. Remove the valve collets (1) and withdraw the pushrods (2).

25100

81 37. Unscrew the cylinder head bolts (1) and remove the head using a hoist and lifting hook 380000216. 38. Remove the cylinder head gasket.

25101

1 82

SECTION 10 -- ENGINE -- CHAPTER 1

39. Rotate the engine upside down on the rotary stand.

NOTE: For disassembly and assembly of the rotating counterweight dynamic balancer see Rotating Counterweight Dynamic Balancer in this chapter. 40. Remove the sump pan bolts, the sump pan (1) and gasket (2). Unscrew the retaining bolts and remove the oil pick-up pipe (1) complete with the strainer and seal.

25102

41. Unscrew the retaining bolts (2) and free the counterweight housing (3) by moving it outward. Remove the sleeve coupling (4) and housing.

25103

2 84

42. Remove the half-gaskets (1) and (3) between the crankcase and sump pan and the gasket (2) between the timing gear carrier and sump pan.

25104

3 85

43. Remove the gasket (1) between the flywheel carrier and the sump pan. NOTE: When relocating gaskets (1) and (3) (fig. 85), apply good quality silicone sealing compound to the mating surfaces.

25105

SECTION 10 -- ENGINE -- CHAPTER 1 44. Remove the rotating counterweight oil seal O-ring (1) installed on the crankcase mating surface.

25106

45. Unscrew retaining bolts (1) and remove the complete oil pump unit.

NOTE: For turbocharged models, see fig. 105 page 47.

25107

88 46. Unscrew the retaining bolts (2) and remove the crankshaft pulley (1).

2 25108

47. Straighten the lock tab that prevents rotation of the crankshaft and unscrew nut (1).

1 25109

SECTION 10 -- ENGINE -- CHAPTER 1

48. Pull the pulley hub off the crankshaft using tool 380000226 (1) and retain the woodruff key for reinstallation.

1 25110

91 49. Unscrew the retaining bolt (1) and remove the timing cover and gasket.

25111

92 50. Unscrew the retaining bolts and remove the lift pump drive gear carrier (1).

25112

93 51. Remove the circlip (1) and remove the thrust washer and the intermediate gear (2).

NOTE: When installing the intermediate gear see engine timing instructions.

25113

SECTION 10 -- ENGINE -- CHAPTER 1 52. Unscrew the retaining bolts (1) and remove the intermediate gear journal.

25114

53. Unscrew the retaining bolts (4) and remove the camshaft (2) complete with the camshaft gear (1) and the end plate (3).

4 3

25115

54. Remove the circlip (1) and the thrust washer. Withdraw the gear with fuel supply pump camshaft (2) from the opposite side.

NOTE: This gear transmits drive to the injection pump. On reassembly see timing instructions.

2 25108

97 55. Unscrew the bolts (1) and remove the timing gear case.

25109

SECTION 10 -- ENGINE -- CHAPTER 1

56. Replace the O-ring seal (1) installed in the lift pump drive shaft lubrication line. 57. Remove the crankcase to timing gear case gasket.

25118

58. Rotate the engine on the stand through 90_. Unscrew the big-end cap bolts (2) and remove the big-end caps (1), complete with each half-shell bearing.

2 25119

100 59. Slide the pistons (1) with rings out of the cylinders, complete with connecting rods.

1 25108

101

60. Rotate the engine on the stand through 90_ back to the horizontal position. Unscrew the flywheel bolts and remove the flywheel with the aid of a hoist and hook 380000216. 61. Unscrew retaining bolts and remove the rear oil seal carrier (1) complete with gasket.

25109

102

SECTION 10 -- ENGINE -- CHAPTER 1 62. Unscrew the main bearing cap bolts (1) and remove the main bearing caps with related bearing shells. Remove the thrust washers located on the penultimate main bearing, as shown in the figure. 63. Lift the crankshaft clear of the crankcase using a hoist and nylon sling. Remove the bearing shells, thrust washers and tappets.

25122

103

64. Rotate the engine on the stand 380000301 (2) through 180_. Attach the lifting chain with eye holes to the crankcase as shown in the figure. Raise the hook 380000216 with the hoist so that the lifting chain is under slight tension. Unscrew the bolts securing the crankcase to the stand (2) and mounting bracket (3) (from set 380000313). 65. Lift the engine clear of the stand. 66. Unscrew retaining bolts and remove the rear crankcase housing (1) and its gasket.

25123

104 NOTE: Oil pump for turbocharged models. 67. Remove the retaining screws (4), take off the washers (3) and the engine lubrication oil pump (2) complete with pressure relief valve (1).

1 2 3 4 26106

105

SECTION 10 -- ENGINE -- CHAPTER 1

68. Remove the lubricating oil pipe (3) fig. 107.

69. Remove the circlip (18).

70. Remove the circlip (25) and cover (23) with relative O-ring seal (24). 71. Remove gear (22) from sump. 72. Remove the circlip (2), gear (26) and the two thrust washers (1).

73. Inspect shaft (27). If it shows signs of scoring or wear it must be replaced. 74. Extract the roll pins and remove the counterweight shafts (8) using a suitable drift.

4 5

25159

106

75. Remove the counterweight drive gear (1) fig. 106 by removing the circlip (5) and the carrier retaining bolts (6). 76. Remove circlip (3) and intermediate gear (4) fig. 106.

7 8

28 27 26 25 24 23 25160

22 21 11 20 19 18 17 16 15 14 13 12

Counter-Rotating Dynamic Balancer (TD80D and TD95D Models) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Thrust washers Circlip Lubricating oil pipe for bushing Counterweight rotation shaft Shaft retaining spring pin Carrier for counterweight drive gear Thrust washer Counterweight Counterweight intermediate gear Bolts securing counterweight housing to sump Circlip Counterweight housing Counterweight drive gear Screen filter

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Screen filter retaining bolt Bushing Rigid coupling sleeve Circlip Thrust washer Carrier for gear Thrust washer Counterweight drive gear Cover O-ring seal Circlip Intermediate gear Shaft for gear Bushing

107

SECTION 10 -- ENGINE -- CHAPTER 1 Assembly -

General Preassembly Information After dismantling the engine, clean all parts carefully. To assemble the engine, carry out the disassembly operations described on pages 34 to 48 in reverse order. Tightening torques are specified in the front of this chapter.

IMPORTANT: -

Replace all seals and gaskets at each complete or partial engine rebuild. Lubricate all rotating parts and oil seals with engine oil prior to installation. Lubricate the oil filter mounting seal before installing the filter.

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

Rotating Counterweight Dynamic Balancer

1. Assemble the counterweight components in the housing (2) by carrying out the disassembly operations 74. to 76. in reverse order. Align the positioning marks on the gear (4) and counterweights (1) (indicated by arrows in fig. 108).

24913

2 108

2. Install the intermediate gear (3) fig. 108 with the longer side of its hub towards the casing side; 3. The holes for the roll pins (1) in the counterweight shafts (2) must be aligned with corresponding holes in the casing. 4. Install the counterweight assembly on the sump.

24914

109

SECTION 10 -- ENGINE -- CHAPTER 1

Tappets, Main Bearings and Crankshaft 1. Install the tappets in the crankcase bores. 2. Lubricate the main bearing seats with engine oil and install the half shell bearings (3). 3. Stick the semicircular thrust washers to both sides of the penultimate main bearing with grease.

3 1

25109

2 110

4. Lubricate the upper surfaces of the main bearing shells with engine oil and lower the crankshaft (1) into position. Do not dislodge the semicircular thrust washers previously installed.

24718

111

5. Lubricate the crankshaft journals with engine oil and install the main bearing caps (3) with the half-shells (4). Install the top semicircular thrust washers (2) to the penultimate bearing cap. 6. Rotate the crankshaft (1) a few times to allow the parts to settle into position. 7. Insert the main bearing cap bolts and screw in until the head of the bolt is up against the cap.

25108

112

SECTION 10 -- ENGINE -- CHAPTER 1 8. Tighten all cap bolts (1) to an initial torque of 80 N⋅m (59 ft-lbs).

24720

113

9. Tighten each cap bolt (1) an additional 90o using tool 380000304 (2).

1 2

24744

114

10. Check that crankshaft endfloat does not exceed the value listed in the SPECIFICATIONS table in the beginning of this chapter.

24760

115 Rear Cover Seal, and Flywheel

1. Install the rear oil seal carrier (3) with the outer seal. Tighten retaining bolts (2) to a torque of 25 N⋅m (18 ft-lb). Using a feeler gauge (1), check that the crankshaft flange is coaxial with the carrier.

3 2

24752

116

SECTION 10 -- ENGINE -- CHAPTER 1

2. Install the inner rear oil seal using installer and hand grip 50139 (1).

24761

117

3. Install the flywheel and tighten the retaining bolts (1) to a torque of 40 Nâ&#x2039;&#x2026;m (29 ft-lb).

24762

4. Using tool 380000304 (1), tighten each flywheel bolt (2) through a further 60o.

118

24763

119

SECTION 10 -- ENGINE -- CHAPTER 1 Pistons 1. Lubricate pistons, rings and cylinders with engine oil prior to installing. 2. Install the piston rings using piston ring pliers 380000221. Ensure that the piston ring gaps are offset 180o apart. 3. Install piston ring clamp 380000220 (1) to compress the rings. Ensure that the piston ring gaps remain180o apart. 4. Insert the piston/connecting rod into the cylinder. Ensure that the connecting rod number corresponds with the cylinder number and that the number stamped on the connecting rod is facing away from the camshaft. IMPORTANT: The stamped marking “LP”, located on the top surface of the piston, must be oriented in such a position that it is facing the valve lifters. In this position ONLY will installation be possible.

2 25163

120

5. Install the big-end caps (2) complete with shells to the crankpins and tighten the cap bolts (1) to a torque of 40 N⋅m (29 ft-lbs).

25164

121

6. Using tool 380000304 (1), tighten each big-end cap bolt (2) through a further 60o.

25165

122

7. Rotate the engine on the stand through 180o and clean the upper face of the cylinder block. 8. Bring the pistons (2) up to TDC and, using a dial gauge with a magnetic base (1), check that the piston protrusion from the cylinder block face is within the tolerance limits listed in the SPECIFICATIONS table in the beginning of this chapter. 25166

123

SECTION 10 -- ENGINE -- CHAPTER 1

Synchronizing the Timing Gears 1. Remove the cover and gasket from the flywheel housing inspection window.

25167

124

2. The flywheel is marked in degrees BTDC. Turn the drive shaft to bring cylinder No. 1 to TDC on the compression stroke. Look through the inspection window and check that the notch aligns with the appropriate index mark, according to the type of Bosch pump installed on the tractor.

26107

125

3. Install the timing gears with the reference marks on the mating gears (indicated by the arrows in the figure) aligned.

25169

126

SECTION 10 -- ENGINE -- CHAPTER 1 Counter-Rotating Balancer When installing the counter-rotating weight box, synchronize as follows: 1. Bring piston no. 1 to TDC. 2. Position the rotating counterweights to align the timing reference marks as shown.

25170

127 3. Turn the rotating counterweight unit over and insert the locating pin (2) in the hole. The pin serves to hold the counterweights in the correct timing position during installation of the unit. 4. Using the hoist and a lifting chain, lower the counterweight unit in the seat in the sump.

25171

128

5. Slide the coupling sleeve (1) over the splines of the counterweight drive gear as shown in figure 127. 6. Slide the other end of the coupling sleeve (1) over the splined shaft of the counterweight drive gear (2), until the master spline in the sleeve coincides with the master spline on the shaft (3), as shown in figure 129. 7. Tighten the dynamic balancer housing retaining bolts (1) fig. 128 to a torque of 110 Nâ&#x2039;&#x2026;m (81 ft-lb).

25172

129

SECTION 10 -- ENGINE -- CHAPTER 1

Injection Pump 1. Install the Bosch injection pump and proceed with the injection pump timing in the manner described in Chapter 4 of this section.

2 25181

130 Cylinder Head Gasket Proceed as follows: 1. Before installing the cylinder head, carefully clean and degrease the mating surface of the cylinder block. Locate a new cylinder head gasket (1) with the word UP uppermost.

25173

131

SECTION 10 -- ENGINE -- CHAPTER 1 Cylinder Head Proceed as follows: 1. Lower the cylinder head onto the block and screw in the cylinder head bolts (1) fig. 134, finger tight. Refer to figure 132 for the tightening sequence of the cylinder head bolts. 25174

132

25175

133

2. 1st stage - Tighten the bolts (1) to a torque of 70 Nâ&#x2039;&#x2026;m (51 ft-lbs) in the sequence indicated in figure 132). 3. 2nd stage - Recheck the torque of all the bolts in the sequence indicated in figure 132.

25176

134

4. Using the angular tightening tool 380000304 (1), tighten each bolt (2) in sequence through 90o (3rd stage) and then through a further 90o (4th stage) in the sequence indicated in figure 132.

2 25177

135

SECTION 10 -- ENGINE -- CHAPTER 1

Valve/Rocker Arm Clearance 1. Before installing the rocker cover, adjust the valve clearances as described under Valve Clearance-Adjustment at the end of this Chapter. 2. Tighten the rocker arm adjuster screw locknuts (1) to a torque of 22 N⋅m (16 ft-lbs).

25178

136 Injectors Proceed as follows: 1. Insert the injectors (2) in the respective bores. 2. Position the injector support brackets and install the spherical washers. 3. Screw the bracket retaining nuts (1) to the spherical washers. Tighten the nuts in two stages as follows: 1st stage - tighten nuts to 10 N⋅m (73 ft-lbs); 2nd stage - tighten nuts to 25 N⋅m (18 ft-lbs). 4. Tighten the leak-off pipe unions. 5. Tighten the high-pressure fuel line unions.

1 2 25179

137

SECTION 10 -- ENGINE -- CHAPTER 1 Compression Test In case of poor engine performance, in addition to checking the fuel injection system (injector nozzles and injection pump), also test the compression on each cylinder.

DANGER

Do not use matches, lighters, blow torches or any naked flame as a source of light when inspecting the engine due to the presence of inflammable fluids and vapor. Compression ratio The compression ratio is a measure of the quantity of air drawn into the cylinder and provides an indication of the efficiency of the sealing elements in the cylinder (piston rings and valves). Uniform compression in all the cylinders ensures that they all perform an equal amount of work, provided of course that each cylinder is injected with the same quantity of fuel at the right time. Low compression reduces engine performance, and causes incomplete fuel combustion due to the lack of available combustion air. The engine therefore gives poor performance with excessive fuel consumption, and consequently exhaust smoke and restriction of the exhaust passages. Since the compression ration varies with the temperature of the engine (cold engines produce lower compression values than hot engines), the compression should be tested when the engine is at normal operating temperature. Test engine compression using the compression test kit 380000303 as follows: 1. Run the engine until it reaches normal operating temperature. 2. Switch off the engine. 3. Disconnect the lead from the engine stop solenoid on the injection pump to close the valve and block the flow of fuel to the injectors. 4. Remove the injector from the cylinder being tested. 5. Turn the engine over a few times with the starter motor in order to expel any carbon residue. 6. Install the dummy injector 380000617 in place of the injector removed previously. Use the copper sealing washer. 7. Connect the compression tester 380000303 and take readings while turning the engine over with the starter motor.

On engines in good working order, with the sump oil at approx. 40_C (104_F), at sea level (760 mm of mercury) and at an engine speed of 200 to 280 rpm, the compression should be 25.5 to 27.5 bar (370 to 400 psi). 8. Test the compression on the other cylinders, repeating steps 4, 5, 6 and 7, bearing in mind that: â&#x20AC;˘ The minimum permissible compression on a used engine is 21.6 bar (313 psi). â&#x20AC;˘ The maximum permissible compression difference between cylinders is 3 bar (43 psi). â&#x20AC;˘ Every 100 meters (328 ft) above sea level corresponds to a reduction in compression by about 1%. Uniform Compression Although high compression is important, it is equally important in regards to smooth running, that the compression is the same in all cylinders. Low compression readings: If very low compression readings are obtained on one cylinder it is advisable to repeat the test. Before testing this time, pour about a spoonful of engine oil into the cylinder through the injector bore. Turn the engine over a few times to distribute the oil evenly over the cylinder walls, and then repeat the test. If the second test readings are significantly higher, suspect worn piston rings, out-of-round or damaged pistons. If the second test readings are not higher, the problem will be the valves. On the other hand, if the second test reading shows only a slight improvement, the problem will be due to both the valves and the rings.

SECTION 10 -- ENGINE -- CHAPTER 1

CHECKS, DIMENSIONS AND REPAIRS Cylinder Block

CAUTION

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

Clean all parts carefully before proceeding with the operations described below. Check cylinder wear as follows: -

measure the inside diameter in the area swept by the piston rings (e) (fig.138); measure the inside diameter at the upper and lower ends of this area both parallel to the crankshaft center line (a) and perpendicular to the crankshaft center line (b); compare measurements thus obtained to determine cylinder ovality and taper.

To check piston running clearance, measure the inside diameter of each cylinder in the area (d) (fig.138) along the axis perpendicular to the crankshaft centerline. If ovality or taper exceed 0.12 mm (0.0047 in) or piston coupling play exceeds 0.3 mm (0.011 in), rebore and grind the cylinders to bring them up to one of the sizes shown in the SPECIFICATIONS table in the beginning of this chapter. Pair up the cylinder liners with the pistons of the same dimensions (see SPECIFICATIONS table in the beginning of this chapter).

NOTE: If one of the cylinders requires reboring, all the cylinders must be rebored to the same dimensions. After reboring, restore the 0.5 mm (0.019 in) 30_ chamfer on the cylinder (1).

1 25307

138

SECTION 10 -- ENGINE -- CHAPTER 1 -

Check the ovality of the bore in the block and rebore if necessary to 0.22 mm (0.008 in) oversize. Rebore and ream the cylinder to the specified inside diameter (see SPECIFICATIONS table in the beginning of this chapter).

25308

139

25310

140 Standard dimensions (mm) of cylinder liners and bores in cylinder block and positions for checking liner wear. a,b. Perpendicular positions of dial gauge for cylinder inside diameter. c. Dimension to obtain after press-installing and reaming of cylinder. d. Area for measurement of inside diameter of used cylinder to determine piston running clearance (measured along axis b perpendicular to crankshaft).

Area for measurement of inside diameter of worn cylinder (area swept by piston rings) to determine ovality and taper (measure along axes a and b, respectively parallel and perpendicular to crankshaft). 1,2,3. Points at which to measure inside diameter of new or rebored cylinders along axes a and b. e.

SECTION 10 -- ENGINE -- CHAPTER 1

Crankshaft, Main Bearings and Flywheel

CAUTION

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. Crankshaft Clean parts carefully before proceeding with operations described below. Carefully inspect the crankshaft. A crack of any size necessitates replacement of the crankshaft. Inspect the crankshaft journals and crankpins; slight scoring or seizure marks can be removed with very fine-grade emery cloth. If scoring, ovality or taper exceeds 0.05 mm (.002 in), the crankshaft will have to be reground. Measure journal diameter, fig.141, to determine the nearest undersize (see SPECIFICATIONS table in the beginning of this chapter). After regrinding, restore the journal and crankpin radii and fillets as shown in the details in fig.142 and check that: - main bearing journal and crankpin ovality does not exceed 0.008 mm (.0003 in); - main bearing journal and crankpin taper does not exceed 0.01 mm (.0004 in);

25311

141

C 25313

142 Standard dimensions (mm) of main bearing journals and crankpins, main bearings and semicircular thrust washers. A. B. C.

Crankpin radii and fillets. Normal crankshaft journal radii and fillets. Radii and fillets of crankshaft journal with thrust washers.

SECTION 10 -- ENGINE -- CHAPTER 1 -

with the crankshaft resting on parallel gauge blocks, the maximum misalignment of the main bearing journals does not exceed 0.10 mm (.004 in). See figure 143.

the centerlines of each pair of crankpins lie in the same plane as the main bearing journal centerlines, with a maximum deviation of ď?§0.25 mm (.009 in) as measured perpendicularly to the same plane. See figure 143.

the distances between the outer surfaces of the crankpins and the crankshaft centerline are equal with a tolerance of ď?§ 0.10 mm (0.004 in). See figure 143.

the runout measured with the dial gauge contact point resting on surface (c) or (d), fig.143, does not exceed the value listed in the SPECIFICATIONS table in the beginning of this chapter.

the oil plugs seal against an oil pressure of 14.7 bar (213 psi);

if new plugs are installed, punch-lock in position and recheck oil tightness with the system pressurized.

B C

25315

143 Maximum tolerances for alignment of main bearing journals and crankpin relative to crankshaft centerline and alignment of crankpins relative to main bearing journals A and B Dial gauge positions for checking runout of flywheel mounting flange. C Maximum permissible main bearing journal alignment deviation.

SECTION 10 -- ENGINE -- CHAPTER 1

Main Bearings Check the clearance between the crankshaft journals and bearing shells using a calibrated wire gauge as follows: - ensure all parts are perfectly clean with no traces of oil; - install the half-shells in their respective seats (5); - install the crankshaft; - position lengths of calibrating wire (6) on the crankshaft journals (4) corresponding with the crankshaft centerline. - install the caps (1) complete with half-shells (2) to the respective journals;

2 3

5 25316

144

lubricate the bolts. Secure the main bearing caps with engine oil and tighten to a torque of 80 Nâ&#x2039;&#x2026;m (59 ft-lb).

Main Bearing Cap Bolts When reusing bolts, check that diameter (d) (measured in area (a) shown in fig.145) is greater than 13.5 mm (0.531 in). If not, replace the bolts.

25318

145

remove the caps and determine the bearing clearance by comparing the width of the calibrating wire at the widest point against the scale printed on the packet (3) fig.144, containing the wire; after installing the crankshaft and the bearing caps and bolts, check crankshaft endfloat about the penultimate bearing with a dial gauge (1); if the endfloat exceeds the specified value (see page 7), replace the existing thrust washers with oversizes washers. Refer to SPECIFICATIONS table in the beginning of this chapter. 25317

1 146

SECTION 10 -- ENGINE -- CHAPTER 1

Flywheel

The flywheel attaches to the crankshaft flange by means of self-locking bolts. The starter ring gear is shrunk-fit after preheating, to the register on the engine side of the flywheel.

When replacing the ring gear, heat in oil to 80o to 90oC (176° to 194°F) before installing and position with the bevel on the teeth facing inward towards the starter motor.

The flywheel mounting holes are offset, therefore the flywheel mounts in one position only.

NOTE: To regrind the flywheel, see Section 18.

Lubricate the screws securing the engine flywheel with engine oil, then tighten them to a torque of 40 N⋅m (29 ft-lbs).

25318

147

Flywheel Bolts When revising bolts, check that diameter d (measured in area (a) shown in figs.147 and 148) is greater than 13.5 mm (0.531 in). If not, replace the bolts.

25319

148

SECTION 10 -- ENGINE -- CHAPTER 1

Connecting Rods

WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing, i.e. goggles, gloves and protective shoes. 1. Clean all parts carefully before carrying out the following operations. 2. Check that the bushings in the connecting rod small ends are tight in the bore and flush with the sides of the rods. If necessary, replace the bushings and ream to the specified diameter (A), after installing.

Dimensions (mm) of standard connecting rods, bearing shells, bushings and gudgeon pins A = Dimension required by reaming after installing bushings L = oil port M = oil port

25320

149

3. Check parallelism of small end and big end axes. Maximum permitted tolerance is ď?§ 0.07 mm (0.002 in) measured at 125 mm (4.92 in) from longitudinal axis of the connecting rod. IMPORTANT: Straighten slightly twisted connecting rods with press. Replace severely deformed rods. New connecting rods must be marked with the number of the cylinder in which they are paired. Check the difference in weight of connecting rods in the same engine does not exceed 25 grams (0.88 oz). 4. Check the oil ways (L and M) fig.149 for obstructions such as scale or impurities.

25321

150

SECTION 10 -- ENGINE -- CHAPTER 1

Pistons

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

1. Clean all parts carefully before carrying out the following operations. 2. Determine the degree of piston and cylinder wear by referring to the SPECIFICATIONS table in the beginning of this chapter, and figure 151. 3. If the piston running clearance exceeds 0.30 mm (0.011 in), rebore and ream the cylinders and install oversize pistons and rings (see SPECIFICATIONS table in the beginning of this chapter). In case of piston replacement, check that the weight difference between pistons in the same engine does not exceed 20 grams (0.7 oz). 4. Check that the piston ring groove clearance (b, fig. 151) and the end gap (c, fig. 151) are within the tolerances listed in the SPECIFICATIONS table in the beginning of this chapter. If the end gap is less than that specified, correct by grinding the ends of the piston ring.

25322

Checking Pistons and Rings a. b.

Checking piston diameter at a distance (d) from the base of the skirt. Checking piston ring groove clearance.

c. d.

Checking the end gap with ring in cylinder bore. Distance from base of piston skirt: 57 mm (2.24 in).

151

SECTION 10 -- ENGINE -- CHAPTER 1 A

25323

152 Dimensions (mm) of Standard Pistons, Gudgeon Pins and Rings. A

Measurement to be obtained with ring inserted in cylinder bore.

Piston diameter measured at 57 mm (2.24 in) from the base of the skirt.

When removing or installing piston rings (1), use pliers 380000221 (2).

1 Install rings in grooves in the order indicated in fig.152. NOTE: When installing pistons on connecting rods, check that the clearance between the gudgeon pin and bore in the piston is within the tolerance listed in the SPECIFICATIONS table in the beginning of this chapter. IMPORTANT: The stamped marking “LP”, located on the top surface of the piston, must be oriented in such a position that it is facing AWAY FROM (opposite) the connecting rod stamping (see also previous “Pistons” section).

2 25324

153

SECTION 10 -- ENGINE -- CHAPTER 1

Check that the piston/connecting rod assembly is perfectly square.

If not, replace parts causing the problem.

25108

154

NOTES: -

Oil the pistons, rings, and cylinders before inserting the pistons in the bores.

Before installing the ring clamp 380000220 (1) to compress the rings for insertion in the cylinder, check that the ring end gaps are offset by an angle of 180o i.e., opposite one another.

This enhances compression and ensures oil sealing.

25326

2 155

Big-End Cap Bolts When reusing bolts, check that diameter d (measured in the area (a) shown in figure 156) is greater than 10.5 mm (0.41 in). If not, replace the bolts.

IMPORTANT: Replace the big-end cap bolts whenever disassembling the connecting rods (where possible). 25327

156

SECTION 10 -- ENGINE -- CHAPTER 1

Valves

CAUTION

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

Clean all parts carefully before carrying out the following operations. Use tool 380000302 for valve removal and installation. In the case of minor sealing faults, the valves and seats in the cylinder head may be refaced using pneumatic grinder or universal grinder. In case of more serious defects, reface the seats and grind the valves. After grinding, check that the step below the valve contact band is no less than 0.5 mm (0.019 in).

Dimensions (mm) of valves and valve guides A. Inlet. B. Distance to be obtained by reaming fitted valve guide. C. Exhaust.

25330

157

Tappets Check that the tappets slide freely in their bores without excessive play. In the case of excessive tappet-to-bore clearance, rebore the seats and install oversize tappets (see SPECIFICATIONS table in the beginning of this chapter). Pushrods must be perfectly straight, and the concave contact surface with the rocker arm adjuster screw must not show signs of seizure or excessive wear, otherwise the rod must be replaced. In case of refacing of the contact surfaces, remove as little material as possible.

25329

158

SECTION 10 -- ENGINE -- CHAPTER 1

Camshaft Place the camshaft on two parallel V blocks, as shown. Using a dial gauge with 1/100 mm scale, check that journal runout relative to the axis of rotation does not exceed 0.02 mm (.0007 in). If runout does not exceed 0.02 mm (.0007 in), the camshaft may be straightened using a press; otherwise replace the camshaft. Check cam lift using a dial gauge and compare to:

25328

- inlet valve = 5.97 mm (.235 in)

159

- exhaust valve = 6.25 mm (.246 in) Replace worn bushings using suitable extractors and drifts. Ream to obtain the inside diameter indicated in figure 160.

25331

Dimensions (mm) of camshaft journals and relative seats in cylinder block.

NOTE: The value indicated for the bushing inside diameter is for an installed bushing.

160

SECTION 10 -- ENGINE -- CHAPTER 1

Valve Timing Check To check the valve timing proceed as follows: 1. Check alignment of the timing reference marks on the timing gears as described in Synchronizing the Timing Gears in this chapter. 2. Provisionally set valve clearances to 0.45 mm (0.017 in). 3. Turn the crankshaft and, using a graduated timing disc, check that valves open and close at the angles indicated in the timing diagram. 4. On completion of timing check, set the valve clearances for normal running as listed in SPECIFICATIONS table in the beginning of this chapter. Valve timing diagram. A. Fixed advance (*). 1. TDC. 2. BDC. 3. Inlet. 4. Exhaust. 5. Injection. (*) According to pump type and engine model (see SPECIFICATIONS table in the beginning of this chapter).

25333

161

SECTION 10 -- ENGINE -- CHAPTER 1 Cylinder Head

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 or install valve springs, use the valve spring compressor 380000302.

1. Clean all parts carefully before proceeding with the operations described below. 2. Check that the cylinder head mating surface is flat using a straightedge (2) and feeler gauge (1). If deviations of more than 0.15 mm (0.006 in) are found, the head must be refaced. IMPORTANT: Remove as little material as possible: the maximum depth of material that can be ground from the cylinder head is 0.5 mm (0.019 in).

25108

162

3. Using a dial gauge with magnetic base (1), check the runout of the valve head (2) in the guide and the clearance between the valve stem and guide.

If the clearance exceeds the specified value (see SPECIFICATIONS table), replace the valve and, if necessary, the valve guide.

25108

163

SECTION 10 -- ENGINE -- CHAPTER 1

Rotating Counterweight Dynamic Balancer

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes. 1. Clean All Parts Carefully Before Proceeding With The Operations Described Below. 2. Check Component Wear And Replace Any Defective Parts. When Replacing The Bushings On The Counterweights, Preheat The Counterweights In Oil To A Temperature Of 140o To 160oC (284o 320oF) (Or Dip The Bushings In Nitrogen) Before Shrink-installing In The Bores. Ream The New Bushings After Installing Using A Reamer With Expanding Cutters To The Inside Diameter listed in the SPECIFICATIONS table in the beginning of this chapter.

28 27 26 25 24 22605

23 22 21 20 19 18 17 16 15 14 13 12

Cross-Sectional View of Rotating Counterweight Dynamic Balancer 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Thrust washers Circlip Bushing lubrication tube Counterweight rotation shaft Shaft retaining spring pin Counterweight drive gear carrier Thrust washer Counterweights Intermediate counterweight drive gear Circlip Bolts securing balancer housing to sump Dynamic balancer housing Counterweight drive gear Wire screen filter

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.

Screen filter retaining screw Bushing Sleeve coupling Circlip Thrust washer Carrier for drive box gear Thrust washer Drive box gear for dynamic balancer Cover O-ring seal Circlip Intermediate gear Intermediate gear rotation shaft Bushing

164

SECTION 10 -- ENGINE -- CHAPTER 1 Valve Guides

CAUTION

CAUTION Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS.

With the cylinder head on the test bench, proceed as follows:

1. Enlarge the bore of the valve guide using twist drill 380000276. 2. Place the cylinder head on a suitable support and remove the valve guide using drift 380000219 (1).

25334

165 3. Turn the head upside down, and force-fit the new valve guide with the enlarged bore using drift 380000219 (1) and bush 380000242 (2).

1 2 25335

166 4. Ream out the valve guide bore (2) using reamer 380000222 (1).

1 2

25336

167

SECTION 10 -- ENGINE -- CHAPTER 1

NOTE: When replacing exhaust valve guides you must also carry out the following further operations. 5. Measure the distance (L) between the cylinder head face and the base of the valve guide using a caliper gauge and the special plate of tool 380000277.

25337

168

The depth of taper milling is given by: B-L=C where: B = depth of taper relative to cylinder head face (see fig. 175). L = distance measured between cylinder head face and valve guide base. C = depth of taper milling. Example B = 43.1 mm (1.696 in) L = 34 mm (1.338 in).

Then

43.1 mm - 34 mm = 9.1 mm C = 9.1 mm or 1.696 in - 1.338 in = 0.358 in C = 0.358 in C = (1.696 to 1.716) - 1.338 = 0.358 to 0.377 ins. C = (43.1 to 43.6) - 34 = 9.1 to 9.6 mm. Depth of taper milling. 6. From the upper side of the cylinder head, install guide bushing (1) of tool 380000277 on the guide valve to be milled (2).

25109

169

7. Slide the cutter (1) of tool 380000277, complete with depth stop (2), into the previously located guide bushing until the cutting head is in contact with the valve guide.

2 25339

170

SECTION 10 -- ENGINE -- CHAPTER 1 8. Position the plate (3) of tool 380000277 flush against the cylinder head face and slide the depth stop (2) up to the plate. Measure the distance (A) between the depth stop and the end of the cutter shank (1).

25340

171

9. Position the depth stop (1) at a distance (D) from the end of the cutter shank and fix in place with setscrew (2).

Distance (D) is given by: A-C=D

where: A = the distance between the end of the cutter shank and the depth stop, with the plate flush against the cylinder head. C = the depth of taper milling.

25341

172

D = the distance determining the end of the taper milling. Example A = 45.5 mm (1.791 in) C = 9.1 mm (0.358 in) Then 45.5 mm - 9.1 mm = 36.4 mm D = 36.4 mm or 1.791 in - 0.358 in = 1.433 in D = 1.433 in 10. Turn the cutting tool (2) until the plate (3) is brought up to the cylinder head face by the depth stop (1). IMPORTANT: Before installing the cylinder head, clean it thoroughly to remove all residue from the milling operation.

2 1

25342

3 173

SECTION 10 -- ENGINE -- CHAPTER 1

Valve Seats in Cylinder Head

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

When refacing the valve seats is required, grind as little material as possible. Use a universal valve grinder (1) if available.

25343

174 Dimensions (mm) of valve seats and guide valves. A. Inlet. B. Depth of taper. (relative to cylinder head face) S. Exhaust.

25344

175

SECTION 10 -- ENGINE -- CHAPTER 1 Crankshaft Front Oil Seal Removal

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. Make sure that no one is standing in the vicinity of the load to be lifted.

1. Remove the exhaust pipe and open the hood. 2. Disconnect the negative battery lead. 3. Remove the left and right-hand wire mesh guards (1) from around the fan.

25028

176

4. Remove the hose clamp and detach the bottom radiator hose (1). Drain off the coolant into a suitable container.

25124

177

5. Unscrew the front axle ground cable retaining bolt (1). 6. Disconnect electrical leads from the horn.

1 TRE0035A

178

SECTION 10 -- ENGINE -- CHAPTER 1

7. Disconnect electrical leads (1) from air filter restriction sensor.

11 TRE0620A

179

8. Remove the clamp (1) on the inlet manifold hose.

180

9. Remove the clamp on the air filter hose (1).

1 TRE0620B

181

10. Remove the air filter restriction sensor (1). Disconnect the air tube.

TRE0620B

182

SECTION 10 -- ENGINE -- CHAPTER 1 11. Remove the clamp and disconnect the pipe (1) connecting the air filter to the exhaust aspirator.

25131

183

12. Remove the hose clamp and the top radiator hose (1).

TRE0619A

184

13. Remove the clamp and the hose (1) from the radiator cap.

25133

185

14. Remove the two bolts (1) securing the radiator to the front axle support and remove the bolts, rubber mountings and spacers.

25134

186

SECTION 10 -- ENGINE -- CHAPTER 1

15. Remove the radiator (1) and the upper rubber mountings.

25135

187

16. Loosen the alternator pivot bolt (1).

25136

188

17. Loosen the belt tension adjuster bolt (1) and remove the belt.

25137

189

SECTION 10 -- ENGINE -- CHAPTER 1 18. Remove the radiator fan (1).

1 25138

190

19. Unscrew the retaining bolts (1) and remove the crankshaft pulley.

25139

191

20. Straighten the tab on the lock washer, hold the crankshaft against rotation and unscrew nut (1).

25140

192

21. Remove the pulley hub from the crankshaft using tool 380000226 (1) and retrieve the woodruff key.

25141

193

SECTION 10 -- ENGINE -- CHAPTER 1

22. Remove the oil seal (1) from the seat. Oil Seal Installation To install the front oil seal, proceed as follows: 1. Install the oil seal in the seat. 2. Install the crankshaft pulley hub and retaining nut; bend tab over on lock washer. Do not install without the woodruff key. 3. Install the crankshaft pulley. 4. Install fan. 5. Install the drive belt, adjust tension and tighten alternator bolts. 6. Install the radiator with rubber mountings and secure with retaining bolts. 7. Install the rubber hoses to the coolant pump and the thermostat housing. 8. Connect the hose to the radiator cap. 9. Connect the hood stay bracket to the bracket mounted on the radiator and secure the retaining bolts. 10. Install the hose to the exhaust aspirator. 11. Install the hose connecting the air cleaner to the inlet manifold. Install the air filter restriction sensor. 12. Install the two wire mesh guards around the fan. 13. Fill the radiator with coolant. Refer to Section 00 for proper quantity. 14. Connect the negative battery lead; close the hood.

25142

1 194

SECTION 10 -- ENGINE -- CHAPTER 1 Valve Clearance

Adjustment

CAUTION

Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Disconnect the negative battery lead. 2. Attach lifting chains to the hood (1) using tools 50131 and 50132 and attach the chains to the hoist.

24872

195 3. Disconnect the electrical leads (1) from headlamps (2).

1 2

24873

196

4. Detach the gas struts (1) from the hood.

TRE0603A

197 5. Remove the four hood hinge bolts (1) and lift the hood clear. 1

TRE0604A

198

SECTION 10 -- ENGINE -- CHAPTER 1

6. Remove the hose clamp and detach the hose from the muffler ejector. 7. Unscrew the two screws securing the muffler front support. 8. Unscrew the retaining nuts (1) securing the muffler to the exhaust manifold and remove the muffler.

TRE0618A

199 9. Unscrew the four rocker cover nuts (1) and remove cover.

25305

200

10. Remove the flywheel inspection window cover (1).

25190

201 11. Adjust the clearance between valves and rocker arms using a feeler gauge, spanner (1) and special tool 380000232 (2).

NOTE: Prior to adjustment, position the valves as described below.

25306

202

SECTION 10 -- ENGINE -- CHAPTER 1 Adjust valve clearances as follows: -

Turn the crankshaft until the inlet and exhaust valves of cylinder no. 1 are balanced (start of induction stroke). In this position the pointer will be aligned with the reference mark PMS 1 (TDC 1) on the flywheel.

Check that the clearance between valves and rocker arms on cylinder no. 4 corresponds with the values specified in the table on page 5. Rotate the crankshaft through 360_ and check valve clearances on the opposing cylinder (No. 1).

Repeat this operation for the other valve pairs. Note that the opposing cylinders are 1-4 and 2-3.

12. Install the rocker cover. 13. Install the flywheel inspection window cover. 14. Install the exhaust muffler. 15. Install the hood. 16. Connect the negative battery lead.

SECTION 10 -- ENGINE -- CHAPTER 1

SECTION 10 -- ENGINE -- CHAPTER 2

SECTION 10 - ENGINE Chapter 2 - Cooling System CONTENTS Section

Description

Page

10 402 30

10 402 28

SECTION 10 -- ENGINE -- CHAPTER 2 SPECIFICATIONS

Cooling System Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

water circulation

Radiator on models TD80D . . . . . . . . . . . . . . . . .

3-row vertical pipes with copper fins

Radiator on models TD95D . . . . . . . . . . . . . . . . . . . . . . . .

4-row vertical pipes with copper fins

Fan, attached to coolant pump pulley . . . . . . . . . . . . . . . . . . . . . .

4-blade steel exhauster fan

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

centrifugal vane-type

Engine speed/coolant pump speed ratio . . . . . . . . . . . . . . . . . . .

1:1.403

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

thermostat

Coolant thermometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

colored scale divided into 3 sections

Temperature ranges corresponding to each section: --

initial white section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

30o to 65o C (86o to 149o F)

middle green section (normal working conditions) . . . . . . . .

65o to 105o C (149o to 221o F)

final red section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

105o to 115o C (221o to 239o F) mm (in)

Interference fit between pump impeller and shaft . . . . . . . . . . . . . .

0.017 to 0.059 (.0006 - .002)

Interference fit between fan hub and shaft . . . . . . . . . . . . . . . . . . . .

0.024 to 0.058 (.001 - .002)

Interference fit between front seal bushing and impeller . . . . . . . .

0.012 to 0.058 (.0004 - .002)

SECTION 10 -- ENGINE -- CHAPTER 2

SPECIAL 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. 380000223 X 380000247

Puller for coolant pump impeller. Drift for installation of coolant pump impeller seal.

SECTION 10 -- ENGINE -- CHAPTER 2 SECTIONAL VIEWS

1 2

25364

1 Engine Cooling System A. Detail of coolant circulation with thermostat valve closed B. Detail of coolant circulation with thermostat valve open 1. Thermostat 2. Coolant Pump

3. 4. 5. 6.

Electric thermometer Temperature sender Fan Radiator

SECTION 10 -- ENGINE -- CHAPTER 2

DESCRIPTION AND OPERATION COOLING SYSTEM

Thermometer

The cooling system is fitted with a permanent coolant mixture consisting of water and antifreeze (up to 50% in volume). This mixture prevents freezing down to the following temperatures:

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).

Degrees °C (°F)

-8 (17.6)

-15 (5)

-25 (-13)

-35 (-31)

% in volume of Anti-freeze

This mixture also has antioxidant, anticorrosion, antifoaming and antiscaling properties to ensure long-term protection of the cooling system. The same mixture can be kept in the cooling system for a maximum of 2 years or 1600 operating hours, whichever comes first, after which it must be changed. Radiator Two valves are built into the radiator cap, one compression valve and one depression valve. Check the correct operation of the valves periodically. 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.

WARNING Wear suitable safety clothing and approved face shield and gloves, to avoid burns from hot flushing agent. Run the engine for about an hour to thoroughly flush the cooling system. Turn the engine off, and drain flushing agent through drain plug apeture. If the system is leaking, check the radiator seal by immersing it in a tank of water at a temperature of 20 to 40 °C (68° to 104 °F), blowing air into the radiator at a pressure of 0.98 bar (14.2 psi) for approx. two minutes (repeat the test at least three times).

Thermostat The thermostat is installed in the cylinder head coolant outlet union. The thermostat is not adjustable and must be replaced if it does not meet the temperature specifications. Refer to the Specifications and Data Tables. Thermostatic Switch The thermostatic switch located in the water pump housing at the front of the engine, increases the cold advance performance of the emissionized engine. During engine startup, the cylinders remain slightly cool until the engine warms up to normal operating temperature, during which time engine timing advances slightly to reduce white smoke and emissions. The cold advance thermostatic switch detects when the engine reaches a temperature of 30°C (86°F) and closes to complete a circuit to the automatic advance mechanism on the fuel injection pump.

SECTION 10 -- ENGINE -- CHAPTER 2 OVERHAUL

WATER PUMP Removal

CAUTION

Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Remove the exhaust pipe and open the engine hood. 2. Disconnect the negative battery lead. 3. Remove the wire mesh guards (1) from the left and right-hand sides of the fan.

25028

2 4. Remove the hose clamp, detach the bottom radiator hose (1) and drain off the coolant.

25124

3 5. Remove the retaining bolts (1) from the fan shroud.

25143

SECTION 10 -- ENGINE -- CHAPTER 2 6. Remove the two strips (1) from the sides of the radiator.

25144

5 7. Move the fan shroud (1) towards the engine. 8. Unscrew the three bolts securing the fan to the water pump shaft. Remove the fan and the fan shroud.

25145

6 9. Loosen the alternator pivot bolt (2). 10. Loosen the belt tension adjustment bolt (1).

1 2

25146

7 11. Remove the water pump pulley (1).

25147

SECTION 10 -- ENGINE -- CHAPTER 2

12. Loosen the hose clamp (1) and detach the hose from the water pump.

25148

9 13. Unscrew the belt tension adjustment arm retaining nut (1) and move the alternator outward.

25149

14. Remove pump connection pipe (1) to gain access to the water pump retaining bolt (2).

25150

15. Unscrew the four bolts (1) securing the water pump.

16. Disconnect the pipe from the coolant pump to the thermostat housing, then remove the pump (2).

25151

SECTION 10 -- ENGINE -- CHAPTER 2 Disassembly

CAUTION

Use the appropriate tools for aligning the holes. NEVER USE YOUR HANDS OR FINGERS.

4 5

NOTE: The bearing (9) forms a single piece with the control shaft (10). It is a sealed unit and requires no lubrication during operation. Disassemble the pump as follows: Refer to Figure 13 unless otherwise noted:

6 10

14262

1. Remove the cover (4) and the shaft screw (2) retaining the shaft (10) and bearing (9). 2. Gently tap the end of the shaft (10) on the rotor side (5) to break the film of oxide between the shaft and the rotor. Install extractor 380000223 (1) fig. 14 and remove the rotor.

3. Remove the front sealing bushing (7). 4. Using a punch, extract the shaft (10) complete with bearing (9) and the fan hub (1) from the pump housing (6). 5976

14 NOTE: Remove seal (8) only if worn or defective.

1 5. Check components for wear, and replace if necessary. Assembly Assemble the parts, proceeding as follows: Refer to Figure 13 unless otherwise noted: 1. Install the shaft (10) complete with bearing (9) and hub (1) on the pump housing (6) and secure it with the retaining screw (2), coated with Loctite 242.

21662

2. If changing the seal (8), install the seal into the seat using tool 38000247 (1) fig. 15. 3. Heat the rotor in an air oven until the rotor reaches a temperature of 130-150oC (266 to 302oF) higher than the shaft. 4. Place the rotor on the shaft. Do not damage the bearing (1). Obtain an operating clearance of G = 0.5-0.7 mm (.019 - .027 in). 5. Install the seal (3) and cover (4), fig. 13, then secure with the relevant screws.

21663

SECTION 10 -- ENGINE -- CHAPTER 2

Installation To install the water pump proceed as follows: 1. Install the water pump on the engine and secure with retaining bolts. Ensure the seals on the vertical pipe connecting the pump to the thermostat housing are installed.

2. Install the connection pipe to the pump, and secure the two retaining bolts. 3. Install the water pump pulley and the fan. Install the fan shroud with the two vertical side strips to the radiator. Fix the belt tension adjustment arm. Tighten the alternator pivot bolt.

25152

4. Install the bottom radiator hose to the pipe on the water pump and the radiator. 5. Install the right-hand wire mesh guard. 6. Install the left-hand wire mesh guard. 7. Fill the cooling system from the radiator cap. 8. Install the exhaust pipe. 9. Connect the battery negative (ground) lead.

COOLING SYSTEM THERMOSTAT

Removal

CAUTION

Always use suitable tools to align holes in parts. NEVER USE YOUR FINGERS OR HANDS. 1. Open the hood. 2. Disconnect the negative battery lead. 3. Remove exhaust pipe.

24872

4. Attach lifting chains to the hood (1) using tools 50131 and 50132 and attach the chains to the hoist (refer to Chapter 1 for tooling details).

5. Disconnect the electrical leads (1) from headlamps (2).

1 2

24873

SECTION 10 -- ENGINE -- CHAPTER 2 6. Detach the strut (1) from hood.

TRE0603A

20 7. Remove the four hood hinge bolts (1) and lift the hood clear.

TRE0604A

21 8. Drain the cooling system from the drain plug (1) on the engine block.

1 24804

9. Remove the fan guard (1) from the right-hand side of the radiator.

25028

SECTION 10 -- ENGINE -- CHAPTER 2

10. Unscrew the hose clamp and disconnect the hose (1) connecting the radiator to the thermostat housing.

TRE0619A

24 11. Remove the thermostat housing cover bolts (1).

25156

25 12. Pry the cover (1) off the housing using a screwdriver and remove the cover.

25157

SECTION 10 -- ENGINE -- CHAPTER 2 13. Remove the thermostat valve (1) and gasket. Testing 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 temperatures for accuracy). The thermostat valve, (1), is installed in the cylinder head coolant outlet union is not adjustable. Therefore replace the thermostat if not operating within the temperatures listed in the SPECIFICATIONS table in the beginning of this chapter.

Installation To install the thermostat proceed as follows: 1. Install the thermostat valve in the housing with a new gasket. Install the cover and tighten the retaining bolts. 2. Connect the radiator to thermostat housing hose and secure with hose clamp. 3. Install the fan guard on the right-hand side of the radiator. 4. Install the coolant drain plug in the engine block and replenish coolant. Refer to Section 00 for quantity and proper antifreeze. 5. Lower the hood in place with the hoist and install the four hinge bolts. 6. Connect the hood strut. Attach the electrical connectors to the headlamps. 7. Install the exhaust pipe. 8. Connect the battery negative (ground) lead. 9. Close the hood.

11 25158

SECTION 10 -- ENGINE -- CHAPTER 2

Op. 10 406 10 RADIATOR Removal

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.

1. Open the hood. 2. Disconnect the battery negative cable. 3. Remove the left and right-hand safety guards (1) from around the fan.

25028

28 4. Remove the hose clamp, detach the bottom radiator hose (1) and drain off the coolant.

25124

29 5. Unscrew the front axle earth cable fixing bolt (1). 6. Disconnect electrical leads from the horn.

1 TRE0035A

SECTION 10 -- ENGINE -- CHAPTER 2 7. Disconnect electrical leads from air filter restriction sensor (1).

1 TRE0620A

8. Remove the clamp (1) on the inlet manifold hose.

9. Remove the clamp (1) on the air filter hose.

1 25129

33 10. Remove the air filter restriction sensor (1) and recover the pipe.

25129

SECTION 10 -- ENGINE -- CHAPTER 2

11. Unscrew the clamp and disconnect the pipe (1) connecting the air filter to the exhaust aspirator.

25131

12. Unscrew the hose clamp (1) and remove the top radiator hose.

TRE0619A TRE0613A

13. Unscrew the clamp and remove the pipe (1) from the radiator cap.

25133

14. Unscrew the two bolts (1) securing the radiator to the front axle support and remove the bolts, rubber mountings and spacers.

25134

SECTION 10 -- ENGINE -- CHAPTER 2

15. Remove the radiator (1) and the upper rubber mountings.

25135

39 Installation

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. To refit the radiator proceed as follows: 1. Replace the radiator and secure with the two bolts. 2. Refit the two rubber hoses to the coolant pump and the thermostat housing. Reconnect the pipe to the radiator cap. 3. Reconnect the bonnet stay bracket to the bracket mounted on the radiator and replace the retaining bolts. 4. Install the hose to the exhaust aspirator. 5. Install the hose connecting the air cleaner to the inlet manifold. Refit the air filter clogging sensor. 6. Reconnect the electrical leads to the horn, air filter restriction sensor and the front axle earth lead. 7. Install the two wire mesh guards around the fan. 8. Fill the radiator with coolant. 9. Reconnect the battery negative lead; close the Hood.

SECTION 10 -- ENGINE -- CHAPTER 2

SECTION 10 -- ENGINE -- CHAPTER 3

SECTION 10 -- ENGINE Chapter 3 -- Lubrication System CONTENTS Section

Description

Page

Oil Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SECTION 10 -- ENGINE -- CHAPTER 3 SPECIFICATIONS

Lubrication System Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

forced, with gear pump

1st 50 hr (Break-in Engine Oil) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

10W-40 -- API SE/CC 10W-40

After 50 hr (AMBRA SUPER GOLD Engine Oil) . . . . . . . . . . . . . . .

15W-40 -- Premium Multi-grade NH 330G

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

camshaft

Engine speed/oil pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .

2:1

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

mesh screen on oil pick--up and filter cartridge in delivery line

Normal oil pressure, warm engine running at max speed. TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.9 to 3.9 bar (42 to 56 psi)

TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 bar (87 psi)

Pressure relief valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

built into pump housing

Valve opening pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3.5 bar (50 psi)

mm (in) TD80D

TD95D

Assembly clearance between oil pump drive shaft and bushing .

0.016 to 0.055 (.0006 -- .002)

Clearance between shaft and driven gear . . . . . . . . . . . . . . . . . . . .

0.033 to 0.066 (.001 -- .002)

Tooth backlash between drive and driven gears . . . . . . . . . . . . . . .

0.100 (.004)

Radial clearance between drive and driven gears and housing . .

0.060 to 0.170 (.002 -- .006)

Thickness of drive and driven gears . . . . . . . . . . . . . . . . . . . . . . . .

40.961 to 41.000 (1.612 -- 1.614)

Height of gear seat in pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41.025 to 41.087 (1.615 -- 1.617)

Endfloat between gears and gear housing in pump . . . . . . . . . . .

0.025 to 0.126 (.001 -- .005)

Pressure relief valve spring

-- free length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45 (1.771)

35.9 (1.413)

-- length under load of 45 to 49 N (10.14 to 11.02 lb) . . . . . . . . . . .

37.5 (1.476)

-- length under load of 88 to 94 N (19.84 to 21.16 lb) . . . . . . . . . .

30.5 (1.200)

-- length under load of 127.8 to 141.2 N (28.73 to 31.74 lb) . . . . .

29 (1.141)

-- length under load of 233.4 to 258 N (52.47 to 58 lb) . . . . . . . . . .

23.2 (.913)

SECTION 10 -- ENGINE -- CHAPTER 3

SPECIAL TOOLS

List of specific tools required for the various operations described in this Section. 380000240

Engine oil lubrication pressure test kit.

1. Filler Cap 2. Safety Valve 3. Filter 4. Low Oil Pressure Warning Light

5. Dipstick 6. Oil Pump 7. Oil Pressure Relief Valve 8. Screen Filter on Supply Line

Engine lubrication system (nonturbo engine shown)

SECTIONAL VIEWS

4 SECTION 10 -- ENGINE -- CHAPTER 3

SECTION 10 -- ENGINE -- CHAPTER 3 DESCRIPTION AND OPERATION OIL FILTER The oil filter is of the full-flow, integral paper cartridge type, and is installed on the pump delivery line. Should the line become clogged, the safety valve (2) will open to allow the oil to bypass the filter, thus ensuring that the engine continues to be lubricated, although with unfiltered oil. Replace the cartridge periodically (every 400 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; tighten the cartridge, by hand only, through a further 3/4 turn.

LOW OIL INDICATOR The indicator consists of a control switch and a red warning lamp on the dashboard, which illuminates in the following conditions: -- low oil pressure (the warning lamp also illuminates in normal conditions, without signifying a fault, when the engine is hot and idling at low speed); -- control switch malfunction. 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; -- burned out lamp; -- interruption in wire to the control switch.

SECTION 10 -- ENGINE -- CHAPTER 3 WARNING

Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing -- safety goggles, gloves and shoes.

OIL PUMP In case of replacement, note that the drive shaft (3) and drive gear are supplied ready assembled, with the gear hot force--filled on the shaft.

1. Remove the oil pan.

2. Remove the retaining bolts and oil pump. 3. Check component wear. Refer to the â&#x20AC;&#x153;Specifications Tableâ&#x20AC;?.

Cross-sectional view of engine lubricating oil pump model TD80D -- Naturally Aspirated 1. External drive gear

2. Bushing 3. Drive shaft and gear

4. Driven shaft and gear 5. Pressure relief valve 25354

2 Cross-sectional view of engine lubricating oil pump models TD95D -- Turbocharged

1. Pressure relief valve

2. Spring 3. Pump housing 4. Internal gears

26109

3 3

SECTION 10 -- ENGINE -- CHAPTER 4

SECTION 10 - ENGINE Chapter 4 - Fuel System CONTENTS Section

Description

Page

Fuel Injectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fuel Injector Sleeves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Checking Injector Protrusion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

10 246 14

SECTION 10 -- ENGINE -- CHAPTER 4 SPECIFICATIONS

Fuel System Fuel tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

90.1 L (23.8 gal)

Air cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

dual cartridge dry air filter, with clogged filter indicator with centrifugal pre-filter and automatic dust ejector

Fuel supply pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

double diaphragm

Fuel filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

through mesh filter in fuel supply pump, and replaceable cartridge on delivery line to injection pump

Minimum fuel flow rate with pump shaft rotating at 1600 rpm . .

100 liters/hour (26.42 gallons/hour)

Operated by eccentric cam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

on camshaft

Bosch injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

distributor type

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

centrifugal counterweights

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

hydraulic

Turbocharger (Model TD95D): --

GARRETT type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

TA 3118-0.82 A/R-57 rotating distributor with speed governor and automatic advance regulator

Bosch pump: --

Model TD80D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 4/11 F 1150 L 704

Model TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

VE 4/11 F 1150 L 703

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

counterclockwise

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

1-3-4-2

SECTION 10 -- ENGINE -- CHAPTER 4

Fuel injectors: Bosch type: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

500307714

Nozzle holder type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4791124

Nozzle type: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DLLA 132S 1320

Number of nozzle holes: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Nozzle hole diameter: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5 0.23 0.0090 in (0.23 mm) 3770 to 3944 psi (260 to 272 bar)

Delivery lines for Bosch pump --

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

99449006

Pipe dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6 x 1.75 x 530 (0.23 x 0.07 x 20.86 in)

FUEL SUPPLY PUMP

mm (in)

Eccentricity of drive shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Diameter of drive shaft at bushings . . . . . . . . . . . . . . . . . . . . . . . . . .

31.975 to 32.000 (1.258 - 1.259)

Internal diameter of installed and reamed bushings . . . . . . . . . . . .

32.050 to 32.075 (1.261 - 1.262)

Interference between bushings and seats . . . . . . . . . . . . . . . . . . . .

0.063 to 0.140 (.002 - .005)

Assembly clearance between shaft and bushings . . . . . . . . . . . . .

0.050 to 0.100 (.002 - .004)

Thickness of internal washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1.45 to 1.50 (.057 - .059)

Thickness of external washer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2.93 to 3.00 (.115 - .118)

SECTION 10 -- ENGINE -- CHAPTER 4 SPECIAL TOOLS

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

X 380001601(2) Device for Bosch injection pump timing on engine (with 380000228). X 380000322

Puller for injection pump drive gear.

380000832

Fuel injector sleeve extractor. (w/kit 380000246)

380000246

Injector sleeve overhaul kit.

380000259

Compressor impeller reaction block.

380000829

(M12 x 1.74) tap. (w/kit 380000246)

380000311

Wrench for injection pump delivery line unions.

380000834

Injector sleeve. (w/kit 380000246)

380000254

Injector cleaning kit.

380000370

380000309

Wrench set for injector dismantling.

Waste removal tool. (w/kit 380000246)

380000831

380000310

Hand pump for injector calibration test.

Reamer. (w/kit 380000246)

380000833

X 380000228(1) Dial gauge (1/100 mm, 0.1968 in (5 mm) stroke, â&#x2C6;&#x2026; 1.5748 in (40 mm) with 380001601).

Cutter. (w/kit 380000246)

380000830

Guide bushing. (w/kit 380000246)

(1) The current gauge 380000228 for timing Bosch fuel injection pumps consists of a larger dial indicating face than older versions with the same part number. Special tool 380001601 accommodates both type gauges. (2) The special tool for timing Bosch fuel injection pumps with part number 380001601 will include the following: 1. Stem, indicator (.5 in) [installs into Dial Gauge 380000228] 2. Pin, stainless steel (1.75 in) [installed with current style Dial Gauge 380000228] 3. Pin, stainless steel (2 in) [installed with older version of Dial Gauge 380000228] 4. Adapter, timing [installed into the fuel injection pump and secures Dial Gauge 380000228 in position]

SECTION 10 -- ENGINE -- CHAPTER 4

Tool Part Number 380001601 for timing Bosch Fuel Injection Pump

50044227

TIGHTENING TORQUES PART

Thread

Nâ&#x2039;&#x2026;m

ft-lb

Timing gear case and cover bolts . . . . . . . . . . . . . . . .

Injection pump drive shaft locking bolt . . . . . . . . . . . .

Nuts for injector mounting studs . . . . . . . . . . . . . . . . .

Inspection pump drive gear nut . . . . . . . . . . . . . . . . . .

105

Injection pump mounting bolts . . . . . . . . . . . . . . . . . . .

SECTION 10 -- ENGINE -- CHAPTER 4 DESCRIPTION AND OPERATION

FUEL INJECTION PUMP (BOSCH) Turbocharged Models The turbocharger (1) provides a boost of diesel engine power output by increasing the mass of air inducted by the engine. The turbocharged engine output is considerably higher than the naturally aspirated diesel engine, with little increase in dimensions or engine speed. In a turbocharged engine, exhaust gas drives a turbine within the turbocharger, rather than discharging into the atmosphere. A compressor, which connects to the turbine by means of a shaft, supplies compressed air to the combustion chambers of the engine. As air pressure increases, air temperature also increases.

20040524

Manifold Pressure Compensator (LDA) The fuel injection system on turbocharged diesel engines includes a manifold pressure compensator (LDA). The LDA (1), mounted on top of the fuel injection pump, reacts to the changing air pressure in the intake manifold generated by the exhaust gas turbocharger, and adapts the full-load delivery to the air pressure accordingly.

1 40040547

3 Description The top portion of the LDA incorporates the air pressure connection and the vent bore. Internally, the LDA contains two separate airtight chambers divided by a diaphragm. A compression spring applies pressure on the diaphragm to match the LDA response point to the air pressure of the turbocharger. The opposite end of the spring contains an adjusting nut, which sets spring preload. The diaphragm connects to a tapered sliding pin. A guide pin transfers the movement of the sliding pin to a reverse lever, which in turn changes the setting of the full-load stop. An adjusting screw at the top of the LDA allows for the initial setting of the diaphragm and the sliding pin. IMPORTANT: The LDA is adjusted and set by Bosch. If the LDA requires any type of adjustment, the injection pump with the LDA must be brought to an authorized Bosch specialist.

Power and torque comparison, naturally aspirated and turbocharged engines

Turbocharged engine

20043621

SECTION 10 -- ENGINE -- CHAPTER 4 Operation In the lower speed range of the engine, the air pressure generated by the turbocharger is insufficient to overcome the pressure of the compression spring (1) under the diaphragm (2). Therefore, the diaphragm remains in the initial position. When the air pressure becomes sufficient to overcome spring force, the diaphragm and sliding pin (3) shift against the force of the compression spring. The guide pin (4) changes position and causes the reverse lever (5) to swivel around a pivot. Due to the force exerted by the governor spring (6), a nonpositive connection between the tensioning lever (7), reverse lever (5), guide pin (4) and sliding pin (3) exists. This action results in the tensioning lever following the swivel

movement of the reverse lever, causing the starting lever (8) and tensioning lever to swivel around pivots to shift the control collar in the direction of increased fuel delivery. Fuel delivery adapts in response to increased air mass in the combustion chamber. When air mass decreases, the compression spring pushes the diaphragm upward with the sliding pin. The compensation of the governor lever mechanism reverses direction, which adapts the fuel quantity to the change in air pressure. In case of turbocharger failure, the LDA reverts to the initial position, and the engine operates normally without developing smoke.

2 4 1 3

5 7

20043622

5 Manifold Pressure Compensator (LDA) 1. 2. 3. 4.

Compression Spring Diaphram Sliding Pin Guide Pin

5. 6. 7. 8.

Reverse Lever Governor Spring Tensioning Lever Starting Lever

SECTION 10 -- ENGINE -- CHAPTER 4

All Models Cold-Start Compensation A cold-start compensation module shifts the start of injection in the advance direction, to improve the cold-start characteristics of the turbocharged diesel engine. Operation triggers automatically by means of a temperature sensitive advance mechanism. Mechanical Cold-Start Accelerator (KSB) Description The KSB (detail A) mounts to the pump housing with the stop lever connected through a shaft to an inner lever. An eccentrically mounted ball pin extends into the roller ring. A helical spring and the stop define the initial position of the stop lever. Attached to the top of the stop lever, a cable connects to the automatic advance mechanism (detail B), which mounts to the fuel injection pump.

1 B

20043623

4 6

Operation With the cable (1) not pulled, the helical spring (2) forces the stop lever (3) up against the stop with the ball pin (5) and roller ring (6) in the initial position. The force applied by the cable causes the stop lever (3), shaft (7), inner lever (8) and ball pin (5) to swivel, which changes the roller ring (6) setting to advance the start of delivery. The ball pin engages a slot in the roller ring, preventing the timing device piston (9) from rotating the roller ring any further in the advance direction until exceeding a given engine speed. A control device (4) with a temperature sensitive expansion element converts the engine temperature into a stroke movement.

5 8

NOTE: For any given engine temperature, the automatic advance mechanism provides the optimum start of delivery.

20043624

SECTION 10 -- ENGINE -- CHAPTER 4

Function The temperature switch, located on the right side of the water pump, 3, receives a supply of 12 volts DC from the fuel pump shutoff solenoid. The shutoff solenoid receives power with the key/start switch in the ON position. The temperature switch normally remains OPEN. The temperature switch differs from the naturally aspirated and turbocharged models. On turbocharged equipped engines, the temperature switch consists of a black wire connector, and the switch closes at 30°C (86°F). On naturally aspirated (NA) engines, the switch consists of a blue wire connector, and the switch closes at 55°C (131°F). The NA engine temperature switch allows the 6 degree cold-start advance timing to run a longer period of time.

BSG6387A

A wax element, 1, transmits motion through linkage, 2, to rotate the roller ring, thereby advancing pump timing 5° to 6° for engine cold starting. After starting the engine, the temperature switch closes when coolant temperature within the water pump reaches the prescribed temperature. The temperature sender now supplies power to the KSB heating element. When the wax element heats, the wax expands, and moves the linkage to return the pump timing to the normal setting. BSG6388A

SECTION 10 -- ENGINE -- CHAPTER 4 OVERHAUL

Op. 10 218 30

FUEL INJECTORS Removal

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Always use suitable tools to align holes in parts. Wear suitable safety clothing - safety goggles, gloves and shoes. Proceed as follows: 1. Disconnect the negative battery lead (1).

25532

10 2. Unscrew the pivot bolts (1) from the support (2) and remove the engine hood.

1 2

25533

SECTION 10 -- ENGINE -- CHAPTER 4 3. Unscrew the union (2) on the fuel supply lines and the return lines (1).

25701

12 4. Loosen the retaining bolts and extract the injector (1).

25702

13 Installation

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. 1. Insert the injector in the seat. Tighten the injector nuts to a torque of 25 Nâ&#x2039;&#x2026;m (18 lb-ft). 2. Tighten the union on the fuel supply lines and the return lines. 3. Replace the engine hood. 4. Connect the negative battery lead.

SECTION 10 -- ENGINE -- CHAPTER 4

FUEL INJECTOR SLEEVES Checking Injector Protrusion

CAUTION Handle all parts carefully. Do not put your hands or fingers between parts. Wear suitable safety clothing - safety goggles, gloves and shoes.

1. If the cylinder head face has been reground, check that injector protrusion is within the tolerance limits listed in the SPECIFICATIONS table at the beginning of this chapter. Checking Injector and Valve Height Relative to the Cylinder Head Face a. Checking injector protrusion b. Checking valve stand-in: 0.7 to 1.0 mm (.027 .039 in) (max. permissible stand-in = 1.3 mm [0.051 ins]). 25345

If injector protrusion exceeds the specified limit, the injector sleeve must be replaced using tool kit 380000246. Removal 1. Set distance (A) on tap (2) 380000829 to 9 mm (.354 in) by means of the ring nut (4). Fix the ring nut in position by tightening the set screw (3).

2 3

2. Cut an internal thread in the sleeve to be removed using tap 380000829 (M12 x 11.75). Ensure to cut the thread only in the sleeve.

4 25346

SECTION 10 -- ENGINE -- CHAPTER 4

7 2 1

4 3

8 9

25348

Disassembly, removal of residue, installation and reaming of injector sleeve in cylinder head using tool kit 380000246. 1, 2, and 11 Injector sleeve extractor 380000832. 3. M8 x 1.25 retaining nuts. 4. Waste removal tool 380000370. 5. Injector sleeve dressing tool 380000834. 6. O-ring seals. 2. Install tool 380000832 (2) to the injector mounting studs on the cylinder head by means of nuts (3) (M8 x 1.25), figure 16. 3. Screw shaft (11) fully into the previously cut thread and turn nut (1) to withdraw the injector sleeve from the head, figure 16. 4. Remove any copper residue from inside the head using tool 380000370 (4), figure 16. Installation 1. Install seals (6) fig. 16 onto the new injector sleeve and install the sleeve into the bore. Ensure the sleeve bottoms up against the bottom of the seat in the cylinder head. Dress with tool 380000834 (5), figure 16.

7. 8. 9. 10. 12.

Reamer 380000831. Cutter 380000833. Ring nut. Guide bush 380000830. Injector sleeve.

5. Remove the guide bush, and install the milling cutter 380000833 (8) fig. 16 in the bush. Install the bush in the sleeve (12) and fix in position by turning the ring nut (9) clockwise. 6. Work with the cutter to remove material until the seating is smooth and free from all marks. 7. Remove the cutter and install the injector. Check injector protrusion (see SPECIFICATIONS table in the beginning of this chapter. Cylinder head bolts (fig. 16) When reusing bolts, check that diameter d, measured in area (a), is greater than 11.5 mm (.452 in). If not, use new bolts.

2. Install guide bush 380000830 (10) fig. 16 in the new sleeve (12), securing it in position by turning the ring nut (9) clockwise. Insert reamer (7) 380000831 in guide bush (10) and ream the lower part of the sleeve. 3. Remove the reamer (7) fig. 16 and back-off the ring nut (9) by about 10 mm (.393 in). 4. Press by hand on the ring nut (or tap gently with a rubber mallet) to release the inside of the guide bush 380000830 (10) fig. 16.

25343

SECTION 10 -- ENGINE -- CHAPTER 4

Op. 10 246 14

INJECTION PUMP Removal

WARNING Handle all parts carefully. Do not put your hands or fingers between parts. Always use suitable tools to align holes in parts . Wear suitable safety clothing - safety goggles, gloves and shoes.

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. IMPORTANT: It is possible that the Bosch injection pump may have either a tapered keyed shaft, or a tapered keyless type shaft. Following the procedures below will ensure the correct installation of both types of Bosch injection pumps. Proceed as follows: NOTE: Differences in the procedures of the TD80D naturally aspirated engine, and the TD95D Turbocharged engine for removing the fuel injection pump, are defined in the step in which the difference occurs.

1. Disconnect the negative battery lead (1). 2. Raise the engine hood.

25532

18 3. Detach the throttle cable (1) from the injection pump (TD80D shown).

25705

SECTION 10 -- ENGINE -- CHAPTER 4

4. Disconnect the injector fuel supply pipes (1) to the injectors on the injection pump (TD80D shown). 5. Disconnect the electrical lead (2) from the engine stop solenoid (TD80D shown).

25706

20 6. Disconnect the fuel return line (1) and the injection pump supply line (2) (TD80D shown).

25707

21 7. For model TD95D disconnect the pipe (1) that connects the LDA device to the inlet manifold.

25708

SECTION 10 -- ENGINE -- CHAPTER 4

8. Before removing the injection pump, time and lock the injection pump with cylinder no. 1 at TDC on the compression stroke as indicated in â&#x20AC;&#x153;Checking the Fuel Injection Pump Timing with Pump on the Tractorâ&#x20AC;? in this chapter. After timing is correctly set, loosen the pump shaft-locking bolt (1), remove spacer (2), then retighten bolt.

This will ensure the pump is properly timed and locked before removing from the tractor. NOTE: Wire tie the removed spacer (2), to the injection pump as it is needed to unlock the injection pump shaft when the injection pump is reinstalled.

1 50046209

23 9. Remove the retaining bolts (2) that secure the pump (1) to drive gearbox.

25682

24 10. Remove the cover (1) to access the injection pump drive gearbox. For models with cab and air conditioning; it is necessary to remove the compressor mounting bracket with the drive gearbox cover.

25683

SECTION 10 -- ENGINE -- CHAPTER 4

11. Unscrew the locknut that holds the injection pump to the gears (1). IMPORTANT: If the fuel injection pump was not secured (locked) with the locking bolt before removal, the pump must be properly lock-timed (refer to “Lock-Time the Fuel Injection Pump with Pump Removed from the Tractor”). 12. Extract the injection pump drive gears using tool 380000322 (2) and recover the injection pump with the woodruff key. 27760

NOTE: Some Tier 2 engines produced before serial 988328 may or may not have the woodruff key installed. Because of the confusion the removed key has caused for technicians, the key has been installed again at engine serial number 25910 (engine production date July 29, 2004). IMPORTANT: The woodruff key is not required as long as the nut securing the injection pump drive gear to the tapered pump shaft is tightened to the proper torque of 105 N⋅m (75 ft.-lb). The gear and pump shaft have an interference taper fit so when the nut is tightened properly, the gear will not move on the shaft without the key installed. The Tier 2 Bosch VE injection pump consists of a pump drive shaft-locking bolt and shim. When the locking bolt is loosened, the shim removed, and the bolt retightened, the drive shaft is unable to turn. This allows the pump to be lock-timed with the number one piston at top dead center before removal.

SECTION 10 -- ENGINE -- CHAPTER 4

Installation

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. 1. Assemble the injection pump complete with key, making sure that the reference marks for timing operations coincide, then fix in position by means of the bolts. 2. Perform the steps for Checking the Fuel Injection Pump Timing with Pump on the Tractor. Refer to the Table of Contents. 3. Lock the injection pump drive gear in position, using the nut. Torque the nut to 105 Nâ&#x2039;&#x2026;m (75 ft-lb). 4. Install the injection pump drive gear box access cover and tighten retaining bolts to a torque of 25 Nâ&#x2039;&#x2026;m (18 ft-lb). 5. Assemble the LDA device connection pipe to the inlet manifold (for model TD95D). 6. Connect the fuel supply and return lines to the injection pump. 7. Connect the engine stop solenoid electrical lead. 8. Connect the injection pump fuel supply lines. 9. Connect the throttle lead to the injection pump. 10. Connect the battery negative lead. Lower the engine hood.

SECTION 10 -- ENGINE -- CHAPTER 4 Checking the Fuel Injection Pump Timing with Pump on the Tractor 1. Raise the engine hood panel. 2. Remove the guard protecting the operator from the fan on the right-hand side of the engine. 3. Remove the flywheel inspection window cover (1), located on the rear, left-hand side of the engine. Retain the cover gasket for reinstallation, or discard if worn or defective. If there is no gasket, the cover will require RTV Gasket Maker upon reinstallation.

27 4. Rotate the flywheel clockwise or counterclockwise to line up the pointer with the PMS (Top Dead Center) mark on the flywheel. If needed, use a screwdriver on the ring gear teeth through the flywheel inspection window.

26107

28 5. Verify that the position of flywheel pointer aligns with the true PMS or top dead center of the number one piston. With the flywheel pointer aligned with PMS, ensure the stamping mark on the front crankshaft pulley (1) aligns exactly with the front timing cover (2) mark.

NOTE: The correct mark on the flywheel is the first solid line just below the letters PMS.

1 10040502

SECTION 10 -- ENGINE -- CHAPTER 4

6. Connect a jumper from the positive terminal of the battery to the terminal (1) of the KSB to energize the cold start advance. IMPORTANT: The KSB must remain energized with 12 volts for a minimum of 5 minutes before checking the timing. This allows the wax to melt in the KSB, and ensures the cold-start advance is off. Ensure the KSB remains energized with 12 volts for the remainder of the timing procedure. NOTE: The KSB wax motor is located between the engine and the rear, left-hand side of the injection pump.

10040490

7. Rotate the flywheel clockwise so that the pointer is 6 to 8 degrees (lines) below the PMS timing mark.

NOTE: The KSB linkage (1) will pivot toward the stop (2) once the wax has melted. When not melted, the linkage pivots rearward away from the stop.

2 10040491

31 8. Remove the central plug (1) from the rear of the injection pump. NOTE: The plug supplies an access for the timing tool 380001601 and dial indicator 380000228. NOTE: The current gauge 380000228 for timing BOSCH fuel injection pump consists of a larger dial indicating face than older versions with the same part number. Special tool 380001601 accommodates both type gauges. The special tool 380001601 includes the following four parts: 0.5 in indicator stem, 1.75 in stainless steel pin (for current style dial gauge), 2.0 in stainless steel pin (for older style dial gauge), and timing adapter. 9. Install the correct size stainless steel pin (see note above) into the threaded end of the adapter. Install the adapter into the fuel injection pump and tighten with a wrench. Install the dial indicator stem into the dial indicator, then install the indicator with stem into the end of the adapter and set the preload described in step 10 before securing. 10. Pre-load the dial indicator in the injection pump by rotating the dial indicator clockwise or counterclockwise as needed to reach approximately 2.5 mm (0.0984 in). After establishing the preload, tighten the nut to lock the dial indicator into position.

1 10040492

SECTION 10 -- ENGINE -- CHAPTER 4 11. Ensure the timing tool moves freely by pulling the top knob (1) and gently letting it spring back. The dial indicator must spring back to the 2.5 mm position. When not within specifications, loosen the dial indicator from the adapter and reset the preload.

10040493

33 NOTE: The following steps require two people: 12. Rotate the flywheel clockwise (as viewed from the operator’s seat) while another technician is watching the dial indicator needle. 13. As soon as the flywheel starts rotating, the needle on the dial indicator will begin to drop from 2.5 mm down towards zero. When the dial indicator needle stops dropping (must be before needle reaches zero), stop the flywheel rotation. The fuel delivery plunger inside the injection pump is now at bottom center. 14. Set the dial indicator needle on zero by turning the outer black dial (1).

1 25712

34 15. With another technician watching the dial indicator, slowly rotate the flywheel counterclockwise (as viewed from the operator’s seat) until the flywheel pointer again aligns perfectly with the PMS mark. 16. To ensure correct timing of the pump, the dial indicator needle must rotate and stop at the dimension specified below. The dimensions are as follows: TD80D - 1.47 mm at PMS = 4° ± 0.03° TD95D - 1.00 mm at PMS = 0° ± 0.03° 26107

SECTION 10 -- ENGINE -- CHAPTER 4

If not within specification, perform the following: 17. To access the lower injection pump mounting bolt, place a suitable container under the mechanical primer pump and remove the primer pump (1). Position the pump and supply hose out of the way.

18. Loosen the top and bottom injection pump mounting bolts.

36 19. Loosen the tamper proof mounting bolt (1) at the injection pump with a small hammer and chisel. 20. If the dial indicator needle moved less than the given specification, rotate the injection pump counterclockwise (as viewed from the operatorâ&#x20AC;&#x2122;s seat). If the needle moved more than the given specification, rotate the pump clockwise. 21. Rotate the injection pump until the dial indicator needle moves to the specified measurement. Hold in the injection pump in this position while tightening the top and bottom mounting bolts. Ensure that the dial indicator needle remains on the specified measurement. 22. Tighten the injection pump retaining bolts to a torque of 25 Nâ&#x2039;&#x2026;m (18 ft-lb). 23. Install a new tamper proof bolt. Tighten until the head of the bolt twists off. 24. Remove the jumper wire from the KSB and the positive terminal of the battery. 25. Remove special tool 380000228 (dial gauge) and the four parts of tool 380001601 from the fuel injection pump. Install the central plug. 26. Install the primer pump. 27. Install the gasket (or replace if necessary), or lay a bead of RTV Gasket Maker on the surface around the flywheel inspection window, then install the cover. 28. Operate the primer pump to prime the fuel system. Bleed the fuel system of air. Refer to the Table of Contents for Fuel System Air Bleeding.

10040495

SECTION 10 -- ENGINE -- CHAPTER 4 Lock-Time the Fuel Injection Pump with Pump Removed from the Tractor 1. Fabricate a mounting plate (1) to secure the injection pump in a bench vise. Use a metal piece of 1/4-inch flat stock 5 inches wide by 8 inches long. 2. Drill a 2-inch diameter hole in the flat stock 2.5 inches in from one end and 2.5 inches in from the side. 3. Insert the front (shaft end) of the injection pump into the 2-inch hole of the flat plate. Using the pump mounting holes as a template place three marks on the flat plate. 4. Drill three 3/8- inch diameter holes in the flat plate. 5. Clamp the mounting plate (1) in a vise. Secure the injection pump (2) to the mounting plate using three 5/16-inch x 1-inch bolts and nuts. 6. Place the woodruff key on a hard surface of the workbench. Using a chisel, drive a small mark into both sides of the key. This will ensure the key fits tightly onto the pump driveshaft and prevent the key from sliding out of the pump driveshaft when installing the pump into the engine. 7. Install the woodruff key into the slot in the pump driveshaft making sure that it is correctly positioned and fits tightly.

50044835

2 50044836

SECTION 10 -- ENGINE -- CHAPTER 4

8. Energize the KSB to remove the cold-start timing advance as follows: Using a 12-volt battery and jumper wires, connect the positive terminal of the battery to the KSB (cold-start advance) (1), and the negative terminal of the battery to a clean paint-free location on the pump housing or on the fabricated mounting plate, (2).

50044837

40 9. At this time the KSB advance arm on the side of the pump (1), will be positioned towards the rear of the pump away from the stop (2). When the advance arm is in this position, the pump cam ring is advanced 6 degrees for cold engine starting. The KSB must remain energized with 12 volts until the timing advance has been removed before proceeding. With a fully charged battery this should take approx. 5 minutes to accomplish. After five minutes the advance arm (1), will have moved towards the front of the pump to a position almost contacting the stop (2). The KSB must remain energized with 12 volts during the rest of the lock-timing procedure. The cold-start advance is now removed and you may proceed.

1 2

50044838

Arm Towards Rear

1 2

50044839

Arm Forward

SECTION 10 -- ENGINE -- CHAPTER 4 10. Procure two M14 x 1.50 jam nuts locally. Thread both nuts (2) onto the pump driveshaft, (1) and then lock them together using two 22 mm open end wrenches.

1 50046204

43 11. Install a 22 mm open end wrench on the rear jam nut. Rotate the pump driveshaft in a counterclockwise direction (facing the front of the pump) until the woodruff key slot on the pump driveshaft, (1) aligns just before the number 1 piston timing mark on the pump housing, (2). NOTE: As you rotate the pump driveshaft, there will be a restriction as the pump plunger rides up and down the cam lobes on the cam plate. The pump driveshaft will come to rest and have no restriction on it when rotated to the correct position with the key located just before the timing mark. It is very crucial that the pump driveshaft be rotated in a counterclockwise direction when lock-timing this pump.

50046205

12. Using a 12 mm wrench, remove the plunger access plug in the center of the rear end cap of the pump, (1).

20046206

SECTION 10 -- ENGINE -- CHAPTER 4

13. Install the injection pump timing tool adapter (1) and pin (380001601) into the plunger access plug. Tighten the adapter using a 16 mm wrench.

50046207

46 14. Insert the dial indicator (380000228) (1) into the timing tool adapter (2). Pre-load the indicator needle to 2.5 mm and rotate the face of the dial indicator (3) to zero. NOTE: At this time the pump driveshaft is positioned with the woodruff key just before the timing mark on the pump housing. If you rotate the driveshaft slightly back and fourth you will see the dial indicator needle move above zero but should not go below zero. If the dial indicator goes below zero you must reset the face to zero with the shat in this position. This ensures the plunger inside the pump is at bottom dead center between cam lobes.

3 1

50046208

15. Using a 10 mm socket, loosen the drive shaft locking screw (1) located on the side of the injection pump. Remove the shim plate (2) from behind the head of this bolt.

NOTE: Keep the shim for reinstallation under the lock-timing screw after the pump is installed on the engine. Leave the lock-timing screw loose at this time. 16. Install a 10 mm socket on the drive and set the wrench to a torque of 34 Nâ&#x2039;&#x2026;m (25 ft-lb). 17. While watching the dial indicator needle, slowly rotate the pump driveshaft counterclockwise. The plunger inside the pump will begin to climb up the cam lobe and the dial indicator will rise away from zero. When the dial indicator rotates to the correct setting (see following chart) and select your tractor model) and while being careful to hold the pump driveshaft in position, tighten the lock-timing screw (without shim) to a torque of 34 Nâ&#x2039;&#x2026;m (25 ft-lb).

1 50046209

SECTION 10 -- ENGINE -- CHAPTER 4 Model

Timing at Top Dead Center (PMS)

TD80D

1.47 mm at PMS Âą 0.03 mm

TD95D

1.00 mm at PMS Âą 0.03 mm

18. Remove the jamnuts (2) from the end of the pump shaft while watching the dial indicator needle to be sure the needle does not move. If the dial indicator needle moves this indicates the shaft turned and you will need to reset it. The lock-timing screw (1) will hold the pump driveshaft at this setting as long as you use caution when installing the pump onto the engine.

19. Disconnect the 12-volt battery jumper wires. 20. Remove the dial indicator and timing tool adapter. Loosely install the plunger access plug at this time because the pump to engine timing will need to be verified after the pump is mounted to the engine. 21. Remove the injection pump from the mounting plate. Pump is ready to be installed on the engine.

1 50046209

SECTION 10 -- ENGINE -- CHAPTER 4

FUEL SYSTEM AIR BLEEDING 1. Loosen the bleed plug (1) approximately two turns. Do not unscrew the plug completely.

50 2. Operate the priming lever (1) on the fuel supply pump until the fuel coming out of the bleed plug is free of air bubbles. 3. Tighten the plug and operate the priming lever on the fuel supply pump again. 4. Start the engine and observe for smooth operation.

51 5. To further bleed the fuel system, loosen the union (1) on the injectors one at a time to allow any remaining air to escape.

25713

SECTION 18 -- CLUTCH -- CHAPTER 1

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

Description

Page

SECTION 18 -- CLUTCH -- CHAPTER 1

SPECIFICATIONS CLUTCHES MAIN CLUTCH -- 11 IN./11 IN. (Model TD80) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual clutch consisting of two single dry plate clutches

Operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical: pedal operated main clutch; hand lever operated PTO clutch

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

single Belleville spring disc

Driven plate lining material for main clutch

organic agglomerate cerametallic

Driven plate lining material for PTO clutch (11 in) . . . . . . . . . . . . . .

organic agglomerate

Driven plate thickness: Main Clutch -- Valeo Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . .

(ins) 10.2 to 10.8 (0.4 to 0.425)

(ins)

10.2 to 10.8 (0.4 to 0.425)

-- Valeo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Luk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm mm

(ins) (ins)

7.3 to 7.9 (0.28 to 0.31) 7.3 to 7.9 (0.28 to 0.31)

Clearance between main clutch release sleeve and housing . . .

(ins)

0.050 to 0.151 (0.002 to 0.006)

Clearance between PTO clutch release sleeve and housing . . . .

(ins)

0.050 to 0.151 (0.002 to 0.006)

-- Luk Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . PTO Clutch

SECTION 18 -- CLUTCH -- CHAPTER 1

MAIN CLUTCH -- 12 IN./12 IN. (Model TD95D) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Dual clutch consisting of two single dry plate clutches

Operating system -- Transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical: Pedal-operated

-- PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical: Manual Lever

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

Single Belleville spring disc

Driven plate lining material for main clutch (12 in. Model TD95D)

cerametallic pads

Driven plate lining material for PTO clutch (12 in. Model TD95D)

organic agglomerate

Driven plate thickness: Main Clutch -- Valeo Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . .

(ins)

10.2 to 10.8 (0.4 to 0.425)

(ins)

9.6 to 10.4 (0.378 to 0.409)

-- Valeo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- Luk . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm mm

(ins) (ins)

7.3 to 7.9 (0.287 to 0.311) 7.3 to 7.9 (0.287 to 0.311)

Clearance between clutch release sliding sleeve and support . . .

(ins)

Clearance between PTO clutch release sleeve and support . . . .

(ins)

0.050 to 0.151 (0.002 to 0.006) 0.050 to 0.151 (0.002 to 0.006)

-- Luk Organic agglomerate and cerametallic . . . . . . . . . . . . . . . . . PTO Clutch

SECTION 18 -- CLUTCH -- CHAPTER 1 TIGHTENING TORQUES PART

Thread

Tightening torque Nâ&#x2039;&#x2026;m

ft-lbs

Clutch/flywheel retaining bolts(1, fig. 46) -- Models JX60, JX70, JX80 and JX90 . . . . . . . . . . . . . . . . . . . . . . . -- Model JX95 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25 M 10 x 1.25

25 59

18 43

Release command fork securing bolt (7, fig. 1) . . . . . . . . . . . . . . . .

M 16 x 1.5

157

116

Retaining bolts securing clutch casing to engine (1, fig. 1) . . . . . .

M 12 x 1.25

Clutch housing/engine retaining nuts (3, fig. 1) . . . . . . . . . . . . . . . .

M 12 x 1.25

Nut for sleeve cover fixing stud (6, fig. 1) . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

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. List of specific tools required for the various operations described in this section. 380000236 Tractor dismantling stand. X 380000612 Dowel for centering and adjustment of 11 in./11 in. clutches X 380000292 Dowel for centering and adjustment of 12 in./12 in. clutches. X 380000293 Clutch adjustment 380000292)

gauge

(with

380000256 Set of wrenches for adjustment of levers in 11 in./11 in., Valeo clutches. 380001613 Locating dowel for assembly of clutch housing on engine.

SECTION 18 -- CLUTCH -- CHAPTER 1

SECTIONAL VIEWS VALEO CLUTCHES (11 IN./11 IN. AND 12 IN./12 IN.) A. Nominal distance of transmission clutch Ievers from flywheel face -- 97.5 to 98.5 mm (3.83 to 3.87 in.)

6. Transmission clutch release Ievers 7. Release control sleeves with thrust 8. Thrust bearings

B. Nominal distance of PTO clutch release Ievers from flywheel face -- 122.5 to 123.5 mm (4.82 to 4.86 in.)

9. PTO clutch release Iever adjusting Iink 10. PTO clutch release Iever locknut

C. Nominal PTO clutch release Ievers clearance -2.5 mm (0.98 in.)

11. PTO clutch plate 12. Transmission clutch plate

D. Nominal transmission clutch release Iever clearance -- 2 mm (0.0787 in.)

13. Flywheel bearing

1. Clutch housing capscrews

14. Sleeve control forks

2. Fork lever capscrews

15. Main clutch release lever adjuster.

3. Sleeve cover retaining nuts

16. Transmission clutch release Iever adjusting screw

4. PTO clutch dishspring

17. Adjusting screw locknut

5. PTO clutch release Ievers A B

14 8

5 13 6 12 11 D

TRE0409A

Longitudinal Sectional View of VALEO Clutches

SECTION 18 -- CLUTCH -- CHAPTER 1

Longitudinal section of clutch LUK 11″/11″ (Not for all markets) 1. PTO clutch release lever adjuster.

B A

2. Belleville spring disc. 3. Clutch housing/engine retaining nuts and bolts. 4. PTO clutch release levers. 5. Release sleeves for main and PTO clutch, complete with thrust bearings. 6. Nuts for sleeve cover fixing studs. 7. Release fork retaining bolt. 8. Main clutch release levers. 9. Main friction disc.

10. Main clutch release lever adjuster. 11. PTO friction disc. 12. Bearing on flywheel. D 98 ± 1 mm. Nominal distance of release levers (8) from clutch contact surface on flywheel. D1 139 ± 1 mm. Nominal distance of release levers (4) from clutch contact surface on flywheel. E

Engagement travel: 17 + 2 mm.

Release travel: 8.5 + 2.5 mm.

25163

Longitudinal section of clutch LUK 12″/12″ (Not for all markets) 1. PTO clutch release lever adjuster.

B A

2. Belleville spring disc. 3. Clutch housing/engine retaining nuts and bolts. 4. PTO clutch release levers. 5. Release sleeves for main and PTO clutch, complete with thrust bearings. 6. Nuts for sleeve cover fixing studs. 7. Fork lever retaining bolts. 8. Main clutch release levers. 9. Main friction disc.

10. Main clutch release lever adjuster. 11. PTO friction disc. 12. Bearing on flywheel. D 103 ± 1 mm. Nominal distance of release levers (8) from clutch contact surface on flywheel. D1 144 ± 1 mm. Nominal distance of release levers (4) from clutch contact surface on flywheel. E

Engagement travel: 19 + 2 mm.

Release travel: 9.5 + 2.5 mm.

25371

SECTION 18 -- CLUTCH -- CHAPTER 1

TROUBLESHOOTING Problem Clutch slips.

Possible Cause

Remedy

Worn friction discs, worn flywheel Check and compare the data given in pressure plates, and flywheel the pages indicated; replace any parts which are worn up to or over the worn. limit and adjust levers and clutch control linkage. Belleville spring disc distorted or Replace the Belleville spring disc. otherwise damaged. Friction linings of discs, disc con- Replace friction discs; identify and taminated with oil and grease. eliminate the source of lubricant inside the clutch housing and thoroughly clean the friction surfaces.

Fierce clutch.

Partial seizure of the external con- Check linkage pivots and lubricate. trol linkage. Friction disc distorted.

Replace disc and adjust clutch control lever.

Friction disc with damaged hub Replace friction disc. springs or loose hub rivets. Oil or grease contaminating the Replace the discs, identify and eliminate the source of lubricant inside the friction lining of disc. clutch housing and thoroughly clean the friction surfaces. Clutch sticks and drags.

Clutch disc friction linings or disc Replace discs and adjust the disks. deformed. Seizure of external control linkage.

Check, replace faulty parts and lubricate.

Controls badly adjusted.

Adjust controls.

Clutch noisy when engaged and/ Worn thrust bearing. or disengaged.

Replace bearing.

Friction disc with hub springs da- Replace the friction disc. maged. Clutch pedal stiff.

Partial seizure of external control Check linkage pivots and lubricate. linkages. Partial seizure of pedal pivot.

Check pivot and lubricate.

SECTION 18 -- CLUTCH -- CHAPTER 1

OVERHAUL 11 IN./11 IN. AND 12 IN./12 IN. CLUTCHES Removal To access the clutch it is necessary to separate the engine complete with the front axle from the transmission.

DANGER

Lift and handle all heavy parts using suitable lifting equipment. Make sure that the load is held and supported by suitable slings and hooks. Make sure that no--one is standing in the vicinity of the load.

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

Proceed as follows: 1. Disconnect the negative battery lead (1). 2. Drain off the oil from the gearbox/transmission casing.

25621

4 3. Drain off the coolant from the engine cooling system. 4. Disconnect two flexible hoses from the power steering control cylinder and drain off the oil from the steering system. 5. Remove the front ballast.

TRE0159A

SECTION 18 -- CLUTCH -- CHAPTER 1

6. Raise the hood (1).

TRE0003A

7. Remove the electrical connections (1)

TRE185A

8. Disconnect the oil pipes (1) to the hydrostatic steering control valve.

TRE0028A

9. Disconnect the multimeter cable (1) from the engine and remove the clamp (2).

TRE0410A

SECTION 18 -- CLUTCH -- CHAPTER 1

10. Detach the throttle control spring (1) and remove the throttle lever (2).

2 TRE0411A

11. Detach the cab air--conditioning pipes.

IMPORTANT: Mark the cab heating hoses to facilitate installation before disconnecting. 24892

11 12. Loosen the clamps (1) and disconnect the cab heating pipes (2).

25411

12 13. Remove the clamp (1) from around the lift pump supply and delivery pipes.

25029

SECTION 18 -- CLUTCH -- CHAPTER 1

14. Disconnect the rubber connecting hose (1) at the hydraulic pump.

TRE0184A

15. Disconnect the lift pump delivery line (1).

TRE0412A

15 16. Disconnect the fuel line (1) from the glow plug.

TRE0183A

16 17. Remove the front, center and rear screws securing the front axle drive shaft guard and remove the guard (1).

25038

SECTION 18 -- CLUTCH -- CHAPTER 1

18. Remove circlip (2) and move sleeve (1) in the direction shown by the arrow to disengage it from the splined shaft of the front axle.

25039

19. Remove circlip (2) and move sleeve (1) in the direction shown by the arrow to disengage it from the splined shaft of the drive.

25040

19 20. Remove the retaining bolts and the drive shaft with the shaft support (1).

25041

20 21. Remove the differential lock pin and knob. Remove the mat from the cab floor.

TRE0161A

SECTION 18 -- CLUTCH -- CHAPTER 1

22. Working through the access (1), remove the two nuts and bolts securing the engine to the transmission.

1 TRE0413A

22 23. Remove the four lower engine to transmission mounting bolts (1).

25049

23 24. Position two wedges (3) on the front axle to prevent any movement of the engine about the axle pivot. Position the tractor dismantling stand 380000236 , so that the fixed support (1) is under the rear transmission housing in the area of the engine coupling flange and the mobile support (2) under the engine in the area of the flange attached to the transmission housing.

25050

24 25. Position another mobile stand 380000236 under the front ballast carrier to prevent any possibility of the engine turning or tipping forwards when the transmission housing is removed.

26. Interpose wooden blocks (1) between the stands and the tractor, and turn the stand height adjustment screws to bring the blocks (1) into contact with the tractor. 25051

SECTION 18 -- CLUTCH -- CHAPTER 1

27. Position a fixed stand (1) under the draw bar support and set the hand brake to on.

25052

26 28. Remove the distance collar (1) between the engine and the transmission (where installed).

25055

27 29. Using tool 380000292 (2) ,unscrew the retaining bolts and remove the clutch (1)

25055

SECTION 18 -- CLUTCH -- CHAPTER 1

Installation To install 11 in./11 in. and 12 in./12 in. clutches, proceed as follows: 1. Check condition of ball bearings pressed in flywheel; replace in the event of excessive noise or binding. If needed, install a new bearing pack with grease. Refer to Section 00 for grease specifications. 2. Position the clutch using tool 380000292. Secure the clutch to the flywheel with the six bolts. 3. Adjust the coplanarity of the clutch release levers as described in PTO Clutch Linkage Adjustment at the end of this section. 4. Clean the distance collar and the mating surfaces of the clutch housing, and also scrape all residue of old sealing compound from the mating surface of the engine. 5. Spread Loctite sealing compound on the mating surfaces of the engine and distance collar. Install the distance collar on the studs screwed into the engine.

11. Remove the stands of tool 380000236 from under the engine and the gearbox/transmission and the stand under the drawbar. 12. Install the cab heater pipe union on the clutch/ engine distance collar. Connect the flexible rubber hoses to the union. 13. Connect the flexible power steering pipes at the front axle and add oil to the system. 14. Connect the flexible pipe to the injector fuel leak-off pipe. 15. Install the multimeter and secure the sleeve with the relative clamp. 16. Connect the compressor, condenser and filter/ dryer inside the cab connecting the pipes. 17. Connect all the electrical connections. 18. Connect the throttle cable to the injection pump.

6. Before Connecting transmission casing to engine -- front axle assembly, grease discs hubs.

19. Install the FWD drive shaft and the relative guard.

7. Chock up the rear wheels with wooden wedges, check that the hand brake is fully on and that the fixed and mobile stands are well positioned.

20. Install the front ballast and secure with the vertical lock pin.

8. Install and tighten the bolts securing the clutch housing to the engine.

21. Fill oil to gearbox/transmission.

9. Ensure that no electrical leads or cables are trapped between the two units.

22. Fill the engine coolant system.

10. Rotate the crankshaft by turning the cooling fan to allow the sleeve to engage the splines on the power take--off shaft.

23. Connect the negative battery lead.

SECTION 18 -- CLUTCH -- CHAPTER 1

Disassembly 1. Unscrew the three PTO clutch lever adjustment nuts (1).

24791

29 2. Remove the PTO clutch friction disc (1), the three coil springs (2), and three washers.

2 24792

30 3. Position three clamps (1) at intervals of 120Â° on the clutch body and evenly and progressively compress the Belleville spring disc.

24793

31 4. Remove the six spring retaining clips (1) from the seats.

24794

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

24975

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

24976

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

24977

SECTION 18 -- CLUTCH -- CHAPTER 1

8. Remove the main clutch pressure plate (1).

24978

36 9. Remove the main clutch friction disc (1).

24979

37 10. Remove the PTO clutch control lever springs (1).

24980

38 11. Remove the PTO clutch control lever pivot pins (1).

24981

SECTION 18 -- CLUTCH -- CHAPTER 1

12. Remove the main clutch control lever springs (1).

24982

40 13. Remove the main clutch control lever pivot pins (1).

24983

41 Assembly To assemble, proceed as follows: 1. Install the lever pivot pins and the relative springs. 2. Install the main clutch disc in the clutch housing. 3. Install the main clutch pressure plate and secure to the pins with the bolts. 4. Insert the Belleville spring disc into the housing. Position three clamps at intervals of 120Â° on the clutch body and evenly and progressively compress the spring. Insert the six spring retaining clips. NOTE: Ensure to firmly insert the six spring retaining clips in each respective seat. 5. Install the PTO clutch friction disc, three washers, and the coil springs on the pins and secure with the three PTO clutch lever adjustment nuts (1).

SECTION 18 -- CLUTCH -- CHAPTER 1

CHECKS, MEASUREMENTS AND REPAIRS

WARNING Handle all parts with great care. Never put your hands or fingers between one part and another. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear.

0,5

Dimensions of the Valeo 11 in./11 in. Dual Clutch A ≥ 12.5 mm (0.4921 in.) B ≥ 17 mm (0.6692 in.) C ≥ 87 mm (3.4251 in.) D ≥ 69 mm (2.7165 in.) Dimensions of the Luk 11 in./11 in. Dual Clutch A ≥ 18 mm (0.7086 in.) B ≥ 24.2 mm (0.9527 in.) C ≥ 88.2 mm (3.4724 in.) D ≥ 71.2 mm (2.8031 in.) Flywheel PTO clutch pressure plate. Main clutch pressure plate. Clutch cover.

Dimensions of the Valeo 12 in./12 in. Dual Clutch A ≥ 14 mm (0.5511 in.) B ≥ 16.8 mm (0.6614 in.) C ≥ 87 mm (3.4251 in.) D ≥ 69 mm (2.7165 in.) Dimensions of the Luk 12 in./12 in. Dual Clutch A ≥ 18.7 mm (0.7362 in.) B ≥ 24.6 mm (0.9685 in.) C ≥ 94.3 mm (3.7125 in.) D ≥ 71.3 mm (2.8070 in.) 1. Flywheel. 2. PTO clutch pressure plate. 3. Main clutch pressure plate. 4. Clutch cover. Replace the PTO friction disc or the main clutch friction disc when the linings wear down to the rivet heads. Replace the disc if oil has soaked into the friction linings. Minimum Permissible Dimensions After Refacing 11 in./11 in. and 12 in./12 in. Dual Clutches Check surface condition of the pressure plates and the clutch cover. If necessary, remove up to 1 mm of material from the cast iron friction surfaces of the clutch pressure plates, cover, and flywheel.

D A

25365

0,5

1. 2. 3. 4.

26164

SECTION 18 -- CLUTCH -- CHAPTER 1

When parts (1), (2), (3) and (4) ( figs. 41 and 42) are repaired by removing material, proceed as follows: The maximum permissible depth of refacing the flywheel relative to the nominal thickness is 1 mm.

A B

Valeo 11 in. Flywheel A = 340 mm (13.3858 in.) B = 290 mm (11.4173 in.) C = 78.5 mm (3.0905 in.) Luk 11 in. Flywheel A = 327 mm (12.8740 in.) B = 285 mm (11.2204 in.) C = 78.5 mm (3.0905 in.) Valeo 12 in. Flywheel A = 360 mm (14.1732 in.) B = 321 mm (12.6378 in.) C = 73.5 mm (2.8937 in.) Luk 12 in. Flywheel A = 352 mm (13.8582 in.) B = 313 mm (12.3228 in.) C = 73.5 mm (2.8937 in.) When necessary, reface the friction surfaces of the main clutch pressure plate (3, figure 41) and the clutch cover (4, figure 41). IMPORTANT: To prolong serviceability of the clutch, remove the minimum amount of material possible from the pressure plate and cover when refacing. NOTE: Removal of material cannot be compensated by turning the flywheel contact side of the clutch cover. If the main clutch friction disc slips after previously refacing the pressure plate and clutch cover a number of times, replace the entire clutch assembly.

Restore the external recess of 0.5 mm after refacing flywheels with 11 in./11 in. or 12 in./12 in. dual clutches.

26166

SECTION 18 -- CLUTCH -- CHAPTER 1

Clutch Release Lever Coplanarity Adjustment

1. Install the clutch and PTO disc to the engine flywheel using tool (3) 380000292 (12 in./12 in. clutch) or 380000612 (11 in./11 in. clutch).

2. Tighten bolts (1) to a torque of 25 Nâ&#x2039;&#x2026;m (18 ft.-lb.) for 11 in. clutch or 59 Nâ&#x2039;&#x2026;m (43 ft.-lb.) for 12 in. clutch.

4 25366

3. Install the clutch adjustment gauge 380000293 (2), and adjust the main clutch release levers (4) with a feeler gauge until obtaining a clearance of 0.1 mm (0.004 in.) on all levers.

4. Rotate the gauge 380000293 (2) and adjust the PTO clutch release levers (1) with a feeler gauge until obtaining a clearance of 0.1 mm (0.004 in.) on all levers.

NOTE: Use tools 380000292 and 380000293 when installing 12 in./12 in. dual clutches. Use tool 380000612 when installing 11 in./11 in. dual clutches.

25367

SECTION 18 -- CLUTCH -- CHAPTER 1

Main Clutch Control Linkage Adjustment Check that pedal free travel before clutch release is approximately 40 mm (1.57 in.). If free travel is less than 25 mm (0.98 in.), adjust clutch as follows:

TRE0048A

47 1. Loosen locknuts (1) and rotate sleeve (2) counterclockwise (each sleeve turn is equivalent to 12 mm [0.47 in.] in pedal displacement). 2. Tighten locknuts (1). 3. Check that pedal free travel is 25 mm (0.98 in.).

TRE0044A

48 PTO Clutch Linkage Adjustment (LUK Clutch) Single Lever PTO - TD80D

The only clutch adjustment required is to check and, if necessary, adjust the clutch lever free travel. This is the amount of lever movement from fully released (control cable) position (A) to the point where resistance is first encountered.

The clutch free travel (C, figure 49) must be 2.5 mm (0.0984 in.). When this distance is less or more than 2.5 mm (0.0984 in.), adjust the clutch as follows:

B TRE0171A

1. Move the PTO clutch lever (1) to disengage position (A) (fully raised).

SECTION 18 -- CLUTCH -- CHAPTER 1

2. Loosen the locknut (1) and remove the split pin (2) fig 50. 3. Turn the sleeve (3) to tighten the control cable completely. 4. Slacken the sleeve (3) for 2 turns (approximately 2.5 mm) to lengthen the cable length. 5. Lock the split pin (2) so as to restore the travel with no load to 2.5 mm (0.0984 in.) then tighten the lock nut (1).

50 PTO Clutch Linkage Adjustment (LUK Clutch) Single Lever PTO - TD95D Above adjustment procedure is also the same for this model. The only difference is the connection point of sleeve, (1) fig. 51 and the lever (2) fig. 51. The sleeve (1) fig. 51 is connected to the lever (2) fig. 51 from the upper hole (A) fig. 51.

NOTE: Connection point of the sleeve (1) fig. 51 to the lever (2) fig. 51 is point B, fig. 51 for all the remaining models (TD80D).

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

SECTION 21 -- FRONT TRANSMISSION Chapter 1 -- 12 x 12 Transmission with Synchronized Mechanical Shuttle CONTENT Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Synchronizer Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox/Reduction Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Synchronizer Reverser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Clutch--Reverser Casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

SYNCHRONIZER REVERSER

SPECIFICATIONS

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

Mechanical type spur gear unit, located between the main clutch and the gearbox. Comprised of: 1 driving gear 1 intermediate gear 1 idle gear

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

Hand lever located on left--hand side of the operator

GEARBOX/REDUCTION UNIT Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4 speed, constant--mesh, with synchronizers on all gears

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

helical

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

Ordinary gear train with 3 ranges providing a total of 12 gears

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

spur

Gearbox and Reduction Unit Control . . . . . . . . . . . . . . . . . . . . . . . .

Independent, with two hand levers located on right--hand side of the operator

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

TORQUE VALUES PARTS

Thread

Bolt or nut securing clutch / reverser casing to engine (C1) . . . . .

Torque Settings Nm

ft-lbs

M 12 x 1.25

Sleeve cover retaining nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

Reverser driven shaft cover retaining bolts (C3) . . . . . . . . . . . . . . .

M 8 x 1.25

Reverser driven shaft plate retaining bolts (C4) . . . . . . . . . . . . . . .

M 10 x 1.25

Bolts securing clutch / reverser housing to gearbox / rear transmission (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

TRE0558A

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

SPECIAL TOOLS Warning -- The operations described in this Section can only be carried out using the ESSENTIAL tools marked with an (X). However, for greater safety and to obtain the best results while saving time and effort, it is recommended that these essential tools are used together with the special tools listed here as well as certain tools which are to be made following the sectional drawings given in this manual.

List of special tools required for the various operations described in this Section : 380000236 Tractor dismantling trolley. 380000227 Clutch casing lifting hook. 380000301 Rotating overhaul stand. 380000271 Front support 380000301). 380000272 Rear support 380000301).

bracket

(with

bracket

(with

SECTIONAL VIEWS

TRE0559A

2 Longitudinal View of Synchronizer Reverser 1. 2. 3. 4. 5.

Synchronizer reverser control shaft Seal Roller bearing. Synchronizer reverser driving gear. Roller bearing.

6. 7. 8. 9. 10.

Reverser control synchronizer. Seal. Synchronizer reverser driven gear. Journal for driven gear (8). Seal.

Note -- On assembly apply jointing compound to surfaces X as indicated in Sect. 21.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

TRE0560A

3 Cross-Sectional View of Synchronizer Reverser 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Synchronizer reverser selector fork. Reverser synchronizer. External reverser control lever. Seal. Circlip. Thrust washer. Synchronizer reverser idle gear. Roller bearing. Thrust washer. Seal.

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

Journal of idle gear (7). Stop plate for journals (11 and 13). Synchronizer reverser driven gear. Synchronizer reverser control rod. Spacer. Reverser synchronizer. Detent ball. Spring for detent ball (17). Detent ball retaining bolt.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 DESCRIPTION AND OPERATION

The synchronizer reverser is a mechanical device which makes it possible to obtain 12 forward and 12 reverse gears. It is controlled by a specific lever located on the platform to the left of the operator.

Selection is effected by means of a synchronizer located in the group of gears. The synchronizer reverser is installed inside the clutch casing between the clutch and the gearbox.

The synchronizer reverser is comprised of a group of three spur gears: driving reverser gear, intermediate gear and driven reverser gear.

It is lubricated by the oil in the rear transmission / gearbox.

SYNCHRONIZER REVERSER TROUBLESHOOTING Problems

Possible causes

Spontaneous disengagement of Incorrect adjustment of external the synchronizer reverser levers and linkages.

Adjust correctly.

Synchronizer engagement teeth damaged.

Remove the clutch casing and replace the synchronizer.

Engagement travel incomplete.

Eliminate the cause and restore full engagement travel.

Difficulty in engaging the reverser Incorrect adjustment of external levers and linkages.

Synchronizer reverser noisy

Remedies

Adjust correctly.

Stiffness and / or partial seizure of external levers and linkages.

Check pivot points and lubricate.

Dragging of main clutch.

See Sect. 18.

Synchronizer damaged.

Remove the clutch casing and replace the synchronizer.

Internal controls do not slide freely: rods, forks and sleeves.

Perform the checks and overhaul for needed parts.

Worn or damaged internal part/s. Remove the clutch casing and replace damaged part/s.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 CLUTCH--REVERSER CASING

OVERHAUL

Disassembly 1. Fix the clutch / reverser casing (1) to stand 380000301 (2) using the two brackets 380000271 and 380000272.

24984

4 2. Remove the spring pin and remove the link lever (1) and the internal lever (2).

26185

5 3. Unscrew the retaining bolt (1) and remove the detent ball and spring.

24989

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

4. Remove the circlip (1), then remove the bearing and thrust washers. 5. Remove the synchronizer assembly with selector fork and rod. 6. Remove the reverser driven gear (2) with roller bearings and spacer.

1 2

26186

7 7. Remove the reverser driving gear (1) complete with roller bearings.

24994

8 8. Remove the circlip (1) securing the reverser driving shaft.

24995

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 9. Working from the front of the clutch / reverser casing with an aluminium drift (2), drive out the reverser driving shaft (1) and remove it from the rear of the casing.

9 2

24997

10 10. Detach the retaining springs and remove the sliding sleeves (1).

24999

11. Unscrew the retaining bolts and remove the sleeve cover / support (1).

25000

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

12. Unscrew the two securing bolts (1) of the sliding sleeve control forks (2).

25001

13 13. Remove the external clutch control levers (1) and remove the forks (2).

2 25002

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1 14. Undo the staking and unscrew bolt (1) securing the stop plate for the journal of the reverser driven shaft (2) and the intermediate gear journal. Remove the intermediate gear from the rear of the casing. Assembly To assemble the synchronizer--reverser, proceed as follows: Refer to the illustrations on pages 5 and 6 to check the correct orientation of the various parts. Refer to the torque settings on page 3. 1. Install the intermediate gear journal complete with the various associated parts, and the journal of the reverser driven gear and secure with the relative stop plate and bolt. 2. Install the sliding sleeve control forks on the relative clutch control levers and secure. 3. Install the sliding sleeve cover and support. 4. Install the sliding sleeve assembly to the relative support and secure with the springs. 5. Insert the reverser driving shaft from the rear of the casing and secure it to the clutch / reverser casing with the circlip. 6. Position the reverser driving gear complete with bearings on the driven shaft. 7. Install the reverser driving gear complete with the bearings and spacers. 8. Install the synchronizer assembly complete with control forks, rod, thrust washers and bearing, and secure in position with the relative circlip. 9. Install the detent ball, spring, and bolt in the locked position after covering the bolt using a suitable sealant. 10. Position the internal lever and link lever and fix with the relative spring pin. 11. Remove the clutch / reverser casing from stand 380000301.

11 1

2 25004

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 1

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

SECTION 21 -- FRONT TRANSMISSION Chapter 2 -- 20 x 12 Transmission with Synchronized Mechanical Shuttle and Creeper CONTENT Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Synchronizer Reverser--Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Torque Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Clutch Casing--Synchronizer Reverser and Creeper Unit . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

SPECIFICATIONS SYNCHRONIZER REVERSER--CREEPER UNIT Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical, spur gears, located between engine and gearbox. Comprised of: 1 driving gear 1 intermediate gear 1 idle gear

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

by hand lever located on left--hand side of operator

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

Ordinary gear train with spur gears, located between main clutch and gearbox, in series with the reverser. Provides 20 forward speeds and 12 reverse speeds

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18x26 = 1:5.524 55x47

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

by hand lever located on left--hand side of operator

GEARBOX Gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4--speed constant mesh, synchronized on all gears

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

helical

Range gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ordinary gear train with three ranges for a total of 12 speeds

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

spur gears

Gearbox and range gear controls . . . . . . . . . . . . . . . . . . . . . . . . .

Independent, by two hand levers

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

TORQUE VALUES PARTS

Thread

Bolt or nut securing clutch casing -- reverser and creeper unit to the engine (C1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sleeve cover nuts (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque Settings Nm

ft-lbs

M 12 x 1.25

M 8 x 1.25

Gearbox driving and driven shaft bearings cover screws (C4) . .

M 8 x 1.25

Bolt securing clutch casing -- reverse and creeper unit to the rear transmission--gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

Synchronizer reverser -- creeper unit driven shaft cover nuts (C3)

TRE0561A

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2 SPECIAL TOOLS

WARNING The operations described in this Section can only be carried out using the ESSENTIAL tools marked with an (X). However, for greater safety and to obtain the best results while saving time and effort, it is recommended that these essential tools are used together with the special tools listed here as well as certain tools which are to be made following sectional drawings given in this manual.

List of special tools required for the various operations in this Section : 380000236 Tractor dismantling stand. 380000227 Clutch casing lifting hook. 380000301 Rotating overhaul stand. 380000271 Front bracket (with 380000301). 380000272 Rear bracket (with 380000301).

Support bracket for installation of gearbox driving shaft seal (mark tool 50043) (Dimensions in mm). Part of kit 50043 -- Make tool in UNI C40.

26191

Tool for gearbox driving shaft seal (mark 50137). Make tool in UNI C40.

26192

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

SECTIONAL VIEWS

TRE0562A

3 Longitudinal View of Reverser--Creeper Unit 1. 2. 3. 4. 5.

Reverser and creeper unit control shaft. Seal. Circlip. Creeper unit control gear. Reverser--creeper unit synchronizer.

6. 7. 8. 9. 10.

Gearbox driving shaft control gear. Creeper unit driven gear. Thrust washer. Reverser driven shaft. Seal.

Note -- On assembly apply sealing compound to the surfaces X. Refer to Sec. 21.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

TRE0563A

4 Cross-Sectional Views of Synchronizer Reverser--Creeper Unit 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Reverser control fork. Detent ball. Reverser synchronizer. Seal. External reverser control lever. Creeper unit control fork. Detent ball. External creeper control lever. Seal. Creeper unit control gear.

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

Intermediate gear for reverser. Roller bearing. Journal for gear (11). Seal. Retaining screw for journal (13). Fast speeds lock pawl. Reverser and creeper unit control rod. Reverser synchronizer. Creeper unit control gear. Retaining screw for rod (17).

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

DESCRIPTION AND OPERATION The reverser--creeper unit is a mechanical device providing the possibility to obtain 20 forward speeds and 12 reverse speeds. The creeper unit engages only in slow and middle ranges, a mechanical interlock prevents creeper engagement in the fast ranges. The creeper unit comprises a group of three spurs gears: a sliding control gear, a synchronizer control gear and a driven gear; the unit utilises the same synchronizer as the reverser.

The reverser comprises three spur gears: the reverser driving gear, an intermediate gear and the reverser driven gear; the reverser is engaged by means of a synchronizer located in the gear assembly. The reverser--creeper unit is installed inside the clutch casing between the clutch and the gearbox. Lubrication is provided by the oil contained in the rear transmission--gearbox.

The creeper is installed in series with the reverser and is controlled by a hand lever located on the right-hand side of the operator.

TROUBLESHOOTING Problems

Possible causes

Spontaneous disengagement of External levers and linkages inthe reverser--creeper unit. correctly adjusted.

Adjust correctly.

Synchronizer teeth damaged.

Remove the clutch casing and replace the synchronizer.

Engagement travel incomplete.

Eliminate the cause and restore full travel.

Difficulty in engaging the revers- External levers and linkages iner--creeper unit. correctly adjusted.

Reverser--creeper unit noisy.

Remedies

Adjust correctly.

Stiffness and / or partial seizure of external levers and linkages.

Check pivot points and lubricate.

Main clutch drag.

See Sect. 18.

Synchronizer defective.

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

Internal control elements do not slide freely: rods, forks and sleeves.

Perform the checks and overhaul for needed parts.

Internal component/s worn or de- Remove clutch casing and replace defective parts. fective.

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

CLUTCH CASING--SYNCHRONIZER REVERSER AND CREEPER UNIT

OVERHAUL

Disassembly

WARNING Handle all parts with great care. Never place your hands between one part and another. Wear suitable safety clothing, i.e. safety goggles, gloves and shoes.

1. Remove the cab (where installed) on platform. Refer to Section 90. 2. Remove the clutch casing. Refer to Section 18. 3. Fix the casing to the rotating stand 380000301 using the brackets 380000271 and 380000272.

22893

5 4. Remove circlip (1) and slide out constant mesh gear (2).

1 2

22894

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

5. Remove circlip (1) of reverser transmission driving shaft.

26198

7 6. Remove plug and remove the control lever retaining pin (1).

26199

8 7. Remove the reverser synchronizer assembly (1) together with control forks and gears.

26200

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

8. Remove the driven shaft gear (1) together with the roller bearings and remove the thrust washer.

26201

10 9. Remove the control fork retaining springs (2) and remove the clutch pressure plate bearing assembly (1).

26202

10. Unscrew the retaining screws (2) and remove the control forks (1).

26203

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

11. Unscrew the retaining screw (15, page 6) and remove the reverser intermediate gear assembly (1).

26204

13 12. Unscrew the retaining bolts and remove the cover (1).

22902

13. From the rear of the casing, remove the shaft (1) and bearing.

26205

14. Unscrew the retaining bolts and remove the cover--support (1).

26206

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

15. Remove the circlip (2) and remove the drive-shaft (1) with bearing.

26207

17 16. Remove the circlip (1).

26208

17. Remove the driveshaft seal (1) using a suitable implement.

26209

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

Assembly To assemble all the reverser and creeper components in the casing follow the instructions below : Refer to the illustrations on pages 6 and 7 for the orientation of the various components. Adhere to the torque setting values prescribed on page 3. To install the seal (1, Figure 19), proceed as follows:

WARNING

Always use suitable tools to align holes. NEVER USE YOUR FINGERS OR HANDS.

1. Install the circlip (1, fig. 18) in the seat. 2. Make the bracket 50043 (4) and tool 50137 (5) (see page 4), if not already done. 3. Install the bracket (3) on the clutch casing, insert the installation drift (4) in the seal seat in contact with the circlip (1, fig. 18). 4. Screw in nut (1) to obtain a distance (H) between the bracket and nut of 3.3 -- 3.6 mm (0.1299 -0.1417 in.) and secure with the locknut (5). Note -- Leave the drift (1) with the nut in the position reached on completion of the installation operation, and on future seal installation operations simply check that the distance (H, fig. 20) is as prescribed.

1 5

2 3

26210

5. Remove the drift (1), the bracket (2) and the circlip (1, fig. 18). 6. Locate the new seal in the seat (see page 6 for correct orientation of seal). Install the bracket (2) on the clutch casing and insert the drift in the bracket. 7. Force the seal in until the nut (1, fig. 20) contacts the bracket (2). 8. Dismantle the bracket (2) and remove the drift (1). 9. Install the driveshaft complete with bearing and circlips. 10. Install the cover--support. 11. Install the reverser and creeper driven gear shaft. 12. Install the cover for the driven gear shaft and secure with the relative screws. 13. Install the reverser intermediate gear assembly and secure with the relative screw.

26211

SECTION 21 -- FRONT TRANSMISSION -- CHAPTER 2

14. Install and secure the clutch control forks to the relative levers. 15. Install the pressure plate bearings and hold in place with the relative springs. 16. Install the driven gear complete with bearing and thrust washer. 17. Install the complete synchronizer assembly and secure with the relative circlip. 18. Install the rod retaining screw coated with a suitable sealing compound. 19. Install the gear on the reverser driven shaft and secure with the relative circlip. 20. Remove the clutch casing --reverser and creeper unit from the stand 380000301.

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

SECTION 23 -- FWD TRANSFER BOX Chapter 1 -- FWD Transfer Box CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Drive Shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Transmission Shafts and Guard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Drive Gear Housing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Transfer Box, Unit Removed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

SPECIFICATIONS Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

34/24x24/34= 1 to 1

Relay lever pad width

(ins)

7.978 -- 8.000 (0.314 -- 0.315)

Pad seat width in driven gear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

8.280 -- 8.370 (0.325 -- 0.329)

Pad clearance in seat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

0.280 -- 0. 460 (0.011 -- 0.18)

Relay lever pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

15.973 -- 16.000 (0.628 -- 0.630)

Pivot housing bore in casing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

16.016 -- 16.059 (0.630 -- 0.632)

Pivot clearance in housing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

0.016 -- 0.086 (0.0006 -- 0.003)

-- Free . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

130 (5.11)

-- Under 178.2 to 197.8 N (18.17 to 20.17 kg or 40 to 44 lb ) . . . .

(ins)

142.5 (5.61)

Relay lever detent spring length

DRIVE SHAFT Front drive sleeve adjustment Front drive sleeve shim thickness . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 4 mm

(ins)

2.2. -- 2.5 -- 2.8 -- 3 -- 3.3 -- 3.7 -- 4 -- 4.3 (0.086 -- 0.098 -- 0.110 -0.118 -- 0.129 -- 0.145 -0.157 -- 0.169)

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

TIGHTENING TORQUES

TRE0400A

TRE0401A

1 PART TO BE TORQUED

Thread

Transmission shaft central support retaining bolt ( C12 ) . . . . . . . . Drive gear housing retaining bolt (C13) . . . . . . . . . . . . . . . . . . . . . .

Torque setting Nm

ft-lbs

M 12 x 1.5

M 12 x 1.25

SPECIAL TOOLS IMPORTANT: The operations described in this section must be performed solely with the ESSENTIAL tools marked below with (X). To work in complete safety and to ensure optimal technical results with a minimum of time and effort, they must however be supplemented with the specific tools recommended below and with those to be specially constructed by you and for which the construction diagrams are given in this manual.

380000821 Drive shaft seal key

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

SECTIONAL VIEWS

DESCRIPTION AND OPERATION

TRE0402A TRE0403A

2 Transfer Box

C12 = Drive shaft center bearing capscrew C13 = Axle drive housing capscrew X = On assembly,thoroughly clean and degrease mating surface X . 1. 2. 3. 4. 5. 6. 10. 11.

Brake driven discs Brake linings Brake shoe Driven gear Intermediate gear Needle roller bearing Driven shaft Guide screws

12. 22. 25. 26. 27. 28. 29. 30. 39. 56.

Four -- wheel drive engagement sleeve Detent plunger Roll pin Intermediate shaft Dust excluder Seal Retaining ring Splined driven shaft Drive shaft guard Center bearing

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

OVERHAUL TRANSMISSION SHAFTS AND GUARD Disassembly

WARNING Handle all parts with great care. Do not place hands or fingers between one part and another. Always wear the prescribed safety clothing, including protective glasses, gloves and shoes. To remove, proceed as follows: 1. Disconnect the negative battery lead.

25621

3 2. Remove the front, center and rear screws securing the front axle prop shaft guard and remove the guard (1). 3. Remove circlip (2) fig. 5 and move sleeve (1) in the direction shown by the arrow to disengage it from the splined shaft of the front axle.

Assembly

WARNING

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

25038

4 1. Install and secure the transmission shaft in position

NOTE: Move the front splined sleeve (27) against retaining ring (28). Using a feeler gauge, measure gap between the sleeve and the retaining ring (26) and install shim (S 5) to obtain sleeve end play (L) of 1 to 1.5 mm (see Section 25). 2. Install and secure the guard.

25040

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

DRIVE GEAR HOUSING ASSEMBLY Removal

TRE0404A

6 3. Detach the drive gear engagement control lever (1).

TRE0405B

7 4. Remove the screws (1) that hold the drive gear housing (transfer box) to the transmission housing. 5. Remove the drive gear housing from the transmission housing.

TRE0406A

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

Installation

WARNING

Use suitable tools for aligning holes. DO NOT USE YOUR HANDS OR FINGERS. 1. Refer to the tightening torques shown on page 3. 2. Carefully clean the contact surfaces. 3. Apply sealing compound (approx. 2 mm wide strip) to the contact surface of the drive gear housing. 4. Install the drive gear housing to the transmission housing. 5. Connect the drive gear engagement control lever 6. Replace the transmission oil drain plug. 7. Transmission shafts and guard installation. 8. Install the drive shaft guard.

NOTE: Move the front splined sleeve against the retaining ring. Using a feeler gauge, measure gap between the sleeve and the retaining ring. Install shim to obtain sleeve end play of 1 to 1.5 mm (1/32 to 1/16 in).

26283

9 Mastic application diagram for assembly of drive gear housing to transmission housing.

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

TRANSFER BOX, UNIT REMOVED Disassembly

WARNING Handle all parts with great care. Do not place hands or fingers between one part and another. Always wear the prescribed safety clothing, including protective glasses, gloves and shoes. With the transfer box on the bench, proceed as follows: 1. Transmission shafts and guard removal see page (5) 2. Drive gear housing removal (see page 6)

TRE0120A

10 3. Use the special punch to withdraw the snap ring (1), then the pin (2). Remove the roller bearing, the spacer, the thrust washers and the intermediate gear.

4. Remove the parking brake control lever.

TRE0407A

11 5. Use a screwdriver to remove the dust ring (1).

1 6. Remove the splined driven shaft, complete with parts, parking brake discs and the driven gear.

TRE0408A

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

Assembly

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

TRE0119A

13 1. Insert the shaft in the housing, then assemble the gear unit, washer and circlip. 2. Install the internal lever ,the external lever, the coupling pad and secure in position by means of the washer and relative circlip. 3. Install the bearing and relative circlips 4. Using tool 380000821, fit the seal and dust ring (use the spacer to fit the dust ring ) 5. Perform drive gear housing installation. 6. Perform transmission shafts and guard installation. TRE0118A

SECTION 23 -- MFD TRANSFER BOX -- CHAPTER 1

SECTION 25 -- MFD AXLE -- CHAPTER 1

SECTION 25 - MFD AXLE Chapter 1 - Front Mechanical Axle CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Complete Front Axle Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Steering Knuckle Pins and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Wheel Hub Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Limited-Slip Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Steering Knuckle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Wheel Hub Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Bevel Drive Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Front Axle Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Determining Pinion Shaft Pre-load Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . 31 Determining Pinion Shaft Position Shim Thickness . . . . . . . . . . . . . . . . . . . . . . . . . Pinion Shaft Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Installation and Backlash Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . Differential Bearing Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sealing Compound Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Toe-in Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

32 34 35 36 37 38

SECTION 25 -- MFD AXLE -- CHAPTER 1

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

steering, load bearing structure, pivoting at center

Pinion - differential Ring - Pinion gear ratio: 30 km/h (18.6 MPH): - TD80D and TD95D Models

9/39 = 1:4.3

Ring - Pinion gear ratio: 40 km/h (24.8 MPH): - TD80D and TD95D Models

11/39 = 1:3.54

Backlash between ring gear pair: - TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

(ins)

0.15 - 0.20 (0.006 - 0.007)

Ratio between front wheel revs and rear wheel drive revs - TD80D and TD95D Models

1:3.78

- TD95D High Clear Model

1:3.98

Bevel Drive and Differential - Thickness of pinion bearing adjustment spacer TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 - 2.25 - 2.30 - 2.35 - 2.40 - 2.45 - 2.5 - 2.55 - 2.6 - 2.65 - 2.7 - 2.75 - 2.8 - 2.85 - 2.9 2.95 - 3.00 - 3.05 - 3.1 - 3.15 - 3.2 - 3.25 - 3.3 - 3.35 - 3.4

TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

2.2 - 2.3 - 2.4 - 2.5 - 2.6 - 2.7 - 2.8 - 2.9 - 3.0 - 3.1 - 3.2 3.3 - 3.4 - 3.5

- Clearance between sides of planetary and side pinion teeth . . .

(ins)

0.15 (0.006)

- Thickness of planetary pinion thrust washers . . . . . . . . . . . . . . .

(ins)

1.470 - 1.530 (0.057 - 0.060)

- Thickness of side gear thrust washers . . . . . . . . . . . . . . . . . . . . .

(ins)

1.50 to 1.60 (0.059 - 0.062)

- Thickness of ring gear position adjustment spacer

(continued)

SECTION 25 -- MFD AXLE -- CHAPTER 1 - Diameter of cross pin for planetary pinions TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

3 mm (ins)

23.939 - 23.960 (0.942 - 0.943)

- Side diameter cross pin bore diameter TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . - Clearance between cross pin and bores . . . . . . . . . . . . . . . . . . . .

23.940 - 23.961 (0.903 - 0.943) 0.080 - 0.122 (0.003 - 0.005)

- Diameter of outer axle shafts and corresponding bushes TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

43.961 - 44.000 (1.730 - 1.732)

- Inside diameter of installed bushes TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . - Clearance between axle shafts and bushes . . . . . . . . . . . . . . . .

Axle shafts and steering knuckles

44.080 - 44.119 (1.735 - 1.736) 0.080 - 0.158 (0.003 - 0.006)

mm (ins)

- Diameter of outer axle shafts and corresponding bushes TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

41.975 - 42.000 (1.652 - 1.653)

- Inside diameter of installed front bush TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . .

42.100 - 42.175 (1.657 - 1.660)

- Clearance between pin and bush TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . - Interference install between bushes and respective bores - Thickness of steering knuckle bearing adjuster plates . . . . . . . . Planetary Final Drives

0.100 - 0.200 (0.003 - 0.007) 0.064 - 0.129 (0.002 - 0.005) 0.10-0.15-0.20-0.25-0.30 (.004 - .006 - .008 - .010 - .012)

- Reduction ratio TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . - Driven gear thrust washer thickness

16:(16+62) = 1:4.88 0.77-0.83 (0.030 - 0 .032) (continued)

SECTION 25 -- MFD AXLE -- CHAPTER 1

Axle pivot

mm (ins)

Pivotting angle (on either side ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11o

Center pivot and support end float . . . . . . . . . . . . . . . . . . . . . . . . . .

0.3 - 1.1 (0.011 - 0.043)

Max. wear clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2 (0.078)

Center pivot diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52.652-52.671 (2.079 - 2.073)

Center pivot front bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52.720-52.790 (2.075 - 2.078)

Center pivot working clearance in bushing . . . . . . . . . . . . . . . . . . .

0.049-0.138 (0.002 - 0 .005)

Rear pinion carrier spigot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99.040-99.72 (3.899 - 3.925)

Rear bushing fitted . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

99.146-99.221 (3.903 - 3.906)

Spigot fitted clearance in bushing . . . . . . . . . . . . . . . . . . . . . . . . . . .

0.074-0.181 (0.003 - 0.007)

Axle front and rear thrust washer thickness . . . . . . . . . . . . . . . . . .

4.95-5.00 (0.194 - 0.196)

Turning radius: - Live axle in Brakes on TD80D and TD95D Models . . . . . . . . . . .

4100 (161.41)

- Live axle in Brakes off TD80D and TD95D Models . . . . . . . . . . .

5600 (220.47)

- Live axle out Brakes on TD80D and TD95D Models . . . . . . . . . .

4500 (177.16)

- Live axle out Brakes off TD80D and TD95D Models . . . . . . . . . .

5100 (200.78)

SECTION 25 -- MFD AXLE -- CHAPTER 1

TIGHTENING TORQUES *Refer to page 6 unless otherwise noted. PART

Thread

TD80D and TD95D Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tightening torque Nâ&#x2039;&#x2026;m

ft-lbs

M 40 x 1.5

294

216

Cap screw, differential case to axle casing (C2) . . . . . . . . . . . . . . .

M 12 x 1.25

113

Cap screw, ring gear to differential case (C3) . . . . . . . . . . . . . . . . .

M 12 x 1.25

113

Cap screw, king pin (C4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

113

- models TD80D and TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 75 x 2

392

289

Cap screw, planetary final drive housing (C7) . . . . . . . . . . . . . . . . .

M 10 x 1.25

Cap screw, wheel disc to hub (C8, page 9) . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

260

191

Nut for rim to disc securing bolt . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

216

159

Front axle front and rear pivot support bolt(C9, page 10) . . . . . . .

M 18 x 1.5

392

289

Differential cage support cap bolt (C10) . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

113

Front axle support to engine retaining bolt (C11) . . . . . . . . . . . . . .

M 18 x 1.5

314

231

Cap screw, front brake housing (C12) . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Front axle Lock ring, pinion (C1, page 8)

Steering knuckle capscrew(C5, page 9) - models TD80D and TD95D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wheel hub bearings lock nut (C6):

SECTION 25 -- MFD AXLE -- CHAPTER 1

6 (83 ft-lbs) C3 - 113 N⋅m

(47 ft-lbs) C12 - 64 N⋅m

C4 (*)

(289 ft-lbs) C6 - 392 N⋅m

26125

C7 - 64 N⋅m (47 ft-lbs) C2 - 113 N⋅m (83 ft-lbs)

(216 ft-lbs) C1 - 294 N⋅m

26124

(231 ft-lbs) C9 - 314 N⋅m 26126

C10 - 113 N⋅m (83 ft-lbs)

(231 ft-lbs) C11 - 314 N⋅m

C9 - 314 N⋅m (231 ft-lbs) 1

(*) See page 26-27

SECTION 25 -- MFD AXLE -- CHAPTER 1 SPECIAL TOOLS

WARNING The tools marked below with an (X) are ESSENTIAL for the operations described in this section. To work in safety and obtain the best results whilst saving time and energy, these essential tools should be supplemented by the specific tools listed below and other tools which are to be made from the drawings provided in this manual. List of specific tools required for the various operations described in this section. 380000251 Front axle overhaul stand. 380000227 Hook for removal-installation of the front differential assembly. 292525

Dowels (M 12x 1.25 ) for front axle and cover

380001597 Dowels (M 16x 1.25 ) for removal / installation of front axle wheels. 380000255 Overhaul support for front axle differential casing. 380000249 Universal gauge for positioning of front drive pinion. X 380000463 Pinion bearing adjustment tool. X 380000248 Bevel pinion positioning adjustment tool. X 380000268 Pinion Ring Nut Wrench. X 380000257 Front drive pinion lock key. X 380000252 Wrench for front differential case bearing adjustment nut. X 380000253 Wrench for front differential case bearing adjustment nut. 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. X 38000269

Wheel hub ring nut wrench.

SECTION 25 -- MFD AXLE -- CHAPTER 1

DESCRIPTION OF OPERATION

SECTIONAL VIEWS

TRE0414A

2 Cross-sectional view of front axle differential X S1 S2

= 0.5-1 mm (0.019 - 0.039 ins) = Pinion bearing shim = Pinion position shim

C1 C2 C3

= Pinion bearing lock ring. = Differential carrier cap screw = Ring gear cap screw

Gd, Gs= R.H. and L.H. Differential bearing lock ring

1. 2. 3. 4. 5. 6. 7. 8. 60. 61. 62. 63.

Pinion Seal Pinion bearing spacer Ring gear Axle shaft with universal joint Side gear washers Differential pinion washers Differential pinion journal cap screw Side gear Side gear Differential pinion Differential pinion journal

SECTION 25 -- MFD AXLE -- CHAPTER 1

TRE0415A

3 Cross-sectional view of front axle steering knuckle and hub S3 S4

= King pin bearing shim = Wheel hub bearing shims

= King pin bearing cap screw = Steering knuckle cap screw = Wheel hub bearing lock ring = Final drive housing cap screw = Wheel hub cap screw 9. Bearing carrier cap screw 10. Seal

C4 C5 C6 C7 C8

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

King pin bearing Seal Seal Axle shaft bushing Spacer Thrust washers Planetary wheel journals Planetary wheel shims Side gear

SECTION 25 -- MFD AXLE -- CHAPTER 1

TRE0416A

4 Cross-sectional view of front axle pivot H L S5

= 1 mm (0.039 ins) = 1 to 1.5 mm (0.039 - 0.059 ins) = Sleeve position shim

= Axle pivot support cap screw = Differential bearing cap screw. = Cap screws securing front axle support to engine. 20. Front axle pivot support 21. Front bushing

C9 C10 C11

TD80D and TD95D models have a centrally pivoting front axle with the pivot and the drive shaft coaxial with the longitudinal axis of the tractor. The drive shaft has no universal joints. The differential has two planetary pinions; drive is transmitted to lateral epicyclic final drive units (installed on the wheel hubs) through universal joints which require no maintenance.

22. 23. 24. 25. 26. 27. 28. 29. 30.

Front thrust washer Rear thrust washer Rear bushing Rear axle pivot support Retaining rings Front splined sleeve Retaining rings Drive shaft guard Drive shaft

SECTION 25 -- MFD AXLE -- CHAPTER 1

OVERHAUL COMPLETE FRONT AXLE ASSEMBLY Removal

DANGER Lift and handle all heavy parts using suitable lifting equipment with a sufficient lifting capacity. Check that the assemblies or parts are held firmly and supported by suitable slings and hooks. Make sure nobody is standing near to the load.

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. Proceed as follows: 1. Disconnect the negative battery lead (1).

25621

5 2. Unscrew bolts (1) and remove the front mudguard supports (2).

2 1

25575

SECTION 25 -- MFD AXLE -- CHAPTER 1

3. Attach nylon slings to the front weights (1). Loosen the locking screw from each weight, lift the weights clear of the tractor and place them in a safe position.

TRE0159A

4. Unscrew bolts (1) and remove the drive shaft guard (2).

25576

5. Remove the circlip (1) from the front of the drive shaft. Slide the sleeve rearwards and detach the drive shaft from the front axle.

25584

6. Pass two nylon slings around the front axle and attach them to a hoist.

25580

SECTION 25 -- MFD AXLE -- CHAPTER 1

7. Lift the tractor with the hoist and place a stand under the sump pan.

TRE0417A

11 8. Unscrew unions (1) of the rigid pipes to the power steering cylinders and detach the two flexible hoses.

1 TRE0176A

12 9. Unscrew the wheel bolts and remove the front wheels.

25582

13 10. Unscrew the front axle rear support retaining bolts (1).

25585

SECTION 25 -- MFD AXLE -- CHAPTER 1

11. Unscrew the front axle front support retaining bolts (1).

25586

1 15

12. Using a hoist and two nylon cables (one for each side) detach the front axle from the tractor. Installation

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. 1. Install the axle and bolt the front and rear supports in position. 2. Reconnect the the power steering pipes. 3. Install the front wheels. 4. Raise the front of the tractor using the hoist. 5. Remove the fixed stand. 6. Detach the nylon cables. 7. Reconnect the drive shaft and install the drive shaft guard. 8. Install the two front mudguards. 9. Attach a nylon cable to the front weights, lift, install to the tractor and secure with the locking screws. 10. Reconnect the negative battery lead. 11. Adhere to the tightening torques indicated on page 5.

25583

SECTION 25 -- MFD AXLE -- CHAPTER 1

Disassembly

WARNING

Handle all parts with care. Do not insert hands or fingers between one part and another. Wear suitable safety clothing, i.e. safety goggles, gloves and shoes. NOTE: For overhaul, the front axle should be mounted on stand No. 380000251 25587

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

1 25588

2. Unscrew plug (1) on the left-hand epicyclic final drive casing. Repeat this operation on the right-hand casing.

25589

19 3. Remove the front axle rear support (1). Remove the front support and retrieve the washer.

25590

SECTION 25 -- MFD AXLE -- CHAPTER 1

4. Unscrew the two track rod retaining bolts (1).

25591

5. Using a suitable puller, withdraw the pins from their bores in the stub axle housing and remove the track rod.

24080

6. Remove the circlips (2) from the cylinder rod pivot pins, unscrew the pin retaining bolts of the cylinder (1), withdraw the pins and detach the two cylinders.

Retrieve the four pins, washers, spacers and cylinders, complete with hoses.

25593

23 7. Unscrew the retaining bolts from the left-hand final drive casing cover (1). Screw in the two dowels 380001597 (2), as shown. Using a slide hammer screwed into the oil drain plug hole, detach the cover (1) from the casing.

25594

SECTION 25 -- MFD AXLE -- CHAPTER 1 8. Remove the circlip (1) securing the side gear (2) and remove the gear.

25595

25 9. Remove the inner circlip (1) from the stub axle shaft.

25596

26 10. Remove the staking (1) on the wheel hub bearing lock ring (2).

25597

27 11. Remove the wheel hub bearing lock ring using wrench 380000269 (1).

25598

SECTION 25 -- MFD AXLE -- CHAPTER 1

12. Remove the wheel hub (1) with the ring gear (2). Retrieve all disassembled parts.

25599

29 13. Unscrew the three retaining bolts (1) of the lower pin of the stub axle housing. Recover the lower pivot pin and the related adjustment shims.

25600

30 14. Unscrew the three retaining bolts (1) of the mudguard bracket (2).

25601

31 15. Withdraw the upper pivot pin (1) and detach the stub axle housing (2). Retrieve the disassembled parts.

25602

SECTION 25 -- MFD AXLE -- CHAPTER 1

16. Unscrew the axle shaft retaining bolt and remove the axle shaft.

25604

33 17. Remove bracket (1), unscrew the union (3) and detach the front brake pipe (2).

25605

34 18. Unscrew two of the bolts fixing the pinion-differential support to the axle casing. Screw in the two dowels 292525 (1). Remove the remaining bolts and separate the drive-differential support from the axle casing. Attach a cable (2) to the support and take up the strain with the hoist. Remove the drive-differential support (3) from the axle casing.

25606

19. Install tool 380000255 (1) in the vice on the work bench. Bolt the pinion-differential support on to the tool. Detach the lifting cable.

20. Unscrew the bolt (2) and remove the ring nut lock tab (3).

25607

SECTION 25 -- MFD AXLE -- CHAPTER 1

21. Remove bolts (1) and the left-hand ring nut lock plates (2) and remove the differential. NOTE: Check that the right and left-hand caps are clearly marked as to re-install in the same position before removal.

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

25614

38 23. Straighten the locking tab on the splined shaftlock nut (1).

25615

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

25616

SECTION 25 -- MFD AXLE -- CHAPTER 1

25. Recover the splined shaft detent ball (1).

25617

41 26. Withdraw the pinion shaft (1) from the rear of the casing and recover the spacer, the adjustment shims and the bearing.

25618

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

25619

SECTION 25 -- MFD AXLE -- CHAPTER 1

Assembly 1. Refer to the illustrations on pages 8, 9 and 10 to check the orientation of the various components. 2. Respect the tightening torques prescribed on page 5. 3. Carry out the adjustments described on pages 25 to 29. 4. Install the rear bearing, the seal, the dust seal, the adjustment shims, the spacer and the bevel drive pinion shaft complete with front bearing. 5. Position the detent ball, screw in the bevel drive pinion lock nut and secure in position by staking. Finally, replace the circlip. 6. Install the ring gear-differential assembly, the support caps and tighten the relative bolts 7. Install the front brake friction disc, metal disc hub gear, piston and front brake housing. Tighten the respective bolts.

8. Install the pinion-differential housing on the front axle casing and install the external front brake pipe. 9. Install the axle shaft and relative bolt. 10. Install the stub axle, the adjustment shims, the upper and lower pivot pins, the mudguard bracket and related bolts. 11. Install the wheel hub, the ring gear of the final drive unit and the lock ring. Tighten to the prescribed torque value, while simultaneously turning the wheel hub, to ensure that the bearings are correctly seated. 12. Install the securing and stop circlips, the side gear and the cover of the final drive unit. 13. Install the pins, washers, spacers and steering cylinders. 14. Install the track rod, the front and rear supports and the oil drain plugs.

SECTION 25 -- MFD AXLE -- CHAPTER 1

STEERING KNUCKLE PINS AND BEARINGS Replacement

WARNING Handle all parts with great care. Do not put your fingers or hands between one piece and another. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear. In the event that the steering knuckle pins prove difficult to remove, proceed as follows. 1. Remove the grease nipples and the steering knuckle pin retaining bolts. 2. Install the bolts (1) of tool 380000235. 3. Install the plate (2) of the tool and fix it to the three bolts with nuts (5). 4. Install 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

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

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

24599

SECTION 25 -- MFD AXLE -- CHAPTER 1

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 Disassemble the front final drive. See axle disassembly. 2 Remove the hub casing (1) and the spacer. 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.

46 4

Install tool 380000284 (2) on the hub and install the seal (3) by a few mm using a striker (1).

47 5

Fully install the seal in position using the ring nut and wrench 380000269 (1).

CAUTION Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 6

Remove tool 380000284 from the hub.

Install the front final drive.

SECTION 25 -- MFD AXLE -- CHAPTER 1

LIMITED-SLIP DIFFERENTIAL Operation The differential with limited slip locking (LIM-SLIP) is of the two planetary gear-type. It is provided with two multi-disc clutch assemblies fitted between the side gears and the differential casing. This differential lock device is totally automatic. It requires no manual operation and significantly reduces (but does not completely eliminate) wheel slip. The difference in speed between the side gears and the differential casing when a wheel loses grip and begins to slip, is prevented by the clutch assemblies that are compressed by axial thrust from the pinion torque transmitted to the side gears by means of the teeth on the two planetary gears. These torque values may be different, according to the nature of the ground and the route followed by the tractor. Torque may vary in intensity, thereby proportionally varying the axial thrust on the clutches. This causes the side gears to mesh with the differential casing which, in turn, permits the axle to overcome the unevenness of the ground.

49 LIMITED-SLIP self-locking differential lock

Removal 1. Remove the pinion-differential casing assembly from the front axle and attach to the support 380000255 (4). Lock the support in a vice and proceed with disassembly, as follows.

WARNING Handle all parts with carefully.Do not put your hands or fingers between parts. Wear suitable safety clothing, safety goggles, gloves and footwear. 2. Remove the bolts (2) and the left- and right-hand ring nut lock plates (3). 3. Check that the right and left-hand caps (1) are clearly marked, so as not to mix the parts during reassembly. 4. Remove the left- and right-hand bearing adjustment ring nuts (Gd) from the ring gear. 5. Remove the bolts (Cg), securing the caps (1) and separate the ring gear from the pinion support. 6. If necessary, unscrew the retaining bolts and remove the ring gear.

SECTION 25 -- MFD AXLE -- CHAPTER 1

26 Disassembly

Disassemble the LIM-SLIP self-locking differential lock as follows: 1. Remove the retaining bolts (1) from the differential half-casing. 2. Open the differential casing (6). 3. Remove the half-casing (7) the differential pin (4), complete with the planetary gears (3), the thrust washers (2) and the pins (9). 4. Remove the side gear (5) the friction disc (11), fig. 52, the metal discs (10), fig. 52, and the friction discs (12), fig. 52, from the half-casing (8). 5. Check the wear on the metal discs (10) and the friction discs (11) and (12) - see table below. Replace any parts that show signs of wear. 6. Proceed with the 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 Nâ&#x2039;&#x2026;m (36 ft-lbs).

51 LIM-SLIP self-locking differential lock

Assembly 1. Re-install the ring gear (if previously disassembled) to the half-casing (8). Tighten the bolts (3), fig. 1, page 6, to a torque of 113 Nâ&#x2039;&#x2026;m (83 ft-lbs). 2. Check the rolling torque of the pinion as indicated on pages 33 - 34. 3. Assemble the differential assembly onto the bevel drive support. Make certain that the previously marked differential bearing support caps are in the correct order. Assemble and adjust the pinion shaft bearings as indicated on page 34.

Friction parts detail

LIM-SLIP SELF - locking differential lock friction discs Part no.

Description

Quantity

Thickness mm (ins)

Maximum wear per disc mm (ins)

Metal discs

1.5 (0.059)

Friction discs

2.8 (0.110)

0.10 (0.004)

Friction discs

1.6 (0.062)

0.15 (0.006)

SECTION 25 -- MFD AXLE -- CHAPTER 1 STEERING KNUCKLE

ADJUSTMENTS

WARNING Handle all parts with great care. Do not put your fingers or hands between one piece and another. Wear suitable safety clothing, i.e. safety goggles, gloves and footwear. Install the front axle on stand 380000251 and proceed as follows. 1. Smear grease on the outer races of the bearings and install the upper cover, without the adjustment plate, but with tool 380000235 (2). Tighten the retaining bolts (C5, page 9) to a torque value of: 113 Nâ&#x2039;&#x2026;m (83 ft-lbs).

24076

2. Install the lower cover without the adjustment plate and lubricate the three retaining bolts with engine oil. 3. Gradually tighten the lower cover bolts in sequence, while simultaneously rotating the casing to allow excess grease to escape.

24077

4. Using a torque wrench and tool 380000235 (1), check that the torque required to rotate the casing (ignoring the initial torque) is 15 - 25 Nâ&#x2039;&#x2026;m (11 - 18 ft-lbs).

If the recorded torque is not as specified, adjust by way of the lower cover bolts. 5. Measure the gap (H) created between the lower cover and the casing adjacent to each of the three bolts.

24078

SECTION 25 -- MFD AXLE -- CHAPTER 1

6. Calculate the average of the three values measured. The total thickness of the adjustment shims to be fitted under the lower cover is to be calculated as follows: S3= H - 0.20 mm (.007 ins) If necessary, round up the value to the next 0.05 mm (.001 ins). 7. Partially unscrew the bolts of the lower cover, insert the selected shims (S3, page 10). Tighten the bolts (C4, page 9) to a torque value of: 113 Nâ&#x2039;&#x2026;m (83 ft-lbs). 8. After having rotated the casing a few times to allow the components to bed down, check that the torque necessary to rotate the casing (ignoring the initial torque) is: 118 - 147 Nâ&#x2039;&#x2026;m (87 - 108 ft-lbs). 9. 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. 10. Install the grease nipples in the upper and lower covers and grease the assembly.

24079

SECTION 25 -- MFD AXLE -- CHAPTER 1

WHEEL HUB BEARING Proceed as follows: --

Progressively tighten the ring nut, using the torque wrench and wrench 380000269 (1) to obtain a torque value of 392 N⋅m (289.12432 ft-lb); 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. 57

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 N⋅m (4.3516 ÷ 10.8416 ft-lb) or if measured with a torque meter. Rc = Rt - R = 7.5 ÷ 18.75 kg (41.3554 lb).

If the measurement is less than 5.9 N⋅m (4.3516 ft-lb) or with the torque meter on 4.8 kg (10.5870 lb) it is necessary to replace the affected parts and repeat the check.

Carefully secure the ring nut.

SECTION 25 -- MFD AXLE -- CHAPTER 1

BEVEL DRIVE ADJUSTMENTS Front Axle Differential Backlash between Side and Planetary Pinion Teeth When overhauling the differential assembly it is necessary to adjust the backlash between the teeth of the planetary pinions and the side gears. Proceed as follows: 1. Thoroughly clean the components of the differential to remove any traces of oil which would otherwise prevent accurate backlash measurement. 2. Install the two side gears without thrust washers, 6, fig. 2. 3. Install the planetary pinions complete with thrust washers and pins and screw the pin retaining bolts in by a few turns sufficient to hold the pins in place. 4. Position a dial gauge on the differential housing, as shown. 5. Move the left-hand side gear, 60, fig. 2, to bring it into full contact with the planetary pinion and then push it up against the differential housing, reading the backlash (GL) on the dial gauge.

24597

6. Repeat the above operations to measure the backlash on the right-hand side gear (GR). The endfloat should be 0.25 mm (0.010 ins). Therefore the shims to be inserted in the differential housing are given by: SL = GL - 0.25 mm (0.010 ins) for the left-hand side gear; SR = GR - 0.25 mm (0.010 ins) for the right-hand side gear. 24598

7. Install shims as near as possible to the calculated value and, using a dial gauge and following the procedure described above, check that the backlash of the left and right-hand side gears is approximately 0.25 mm (0.010 ins).

SECTION 25 -- MFD AXLE -- CHAPTER 1

Determining Pinion Shaft Pre-load Shim Thickness Proceed as follows. 1 Clamp tool 380000248 (1) in a vice. Slide the spacer (4) from the bevel assembly onto the tool. Slide the remaining bearing (5) from the bevel assembly onto the tool. Slide the top cone (6) from the tool onto the tool threads. Tighten the tool nut (7) to 1.2 Nâ&#x2039;&#x2026;m (10 in-lbs). NOTE: Tool spacer 50118 (2) supplied with tool 380000248 is not used with TD80D and TD95D front axle. 2

20040461

Using a micrometer, measure distance (H1) between the upper surface of the tool (6) and the top of the threaded pin (7) of tool 380000248 (1).

20040464

61 3

Disassemble the parts mentioned above, lubricate the bearings with engine oil and then reassemble the parts, excluding the bearing spacer (4, fig 60), in the bevel drive-differential housing, complete with outer bearing races. Fully tighten the nut on the tool 380000248 (1) while turning the tool to ensure that the bearings are seated correctly.

Using the micrometer, measure the distance (H2) between the upper surface of the tool (1) and the top of the threaded pin of tool 380000248.

The thickness of the adjustment shim (17 or 19) required is given by: S = H2 - H1 + 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.

SECTION 25 -- MFD AXLE -- CHAPTER 1

Determining Pinion Shaft Position Shim Thickness

Definitions where: H3 =

Distance measured using a micrometer

H4 =

115 mm (4.52 in); nominal distance between the ring gear axis and the large diameter base of the pinion

H5 =

Corrected nominal distance between the ring gear axis and the large diameter base of the pinion

Correction value stamped on pinion preceded by a “+” or “-” (if other than 0), to be added or subtracted from the nominal distance (H4) according to the sign.

Thickness of the adjustment ship (H3 H5)

Proceed as follows. 1

Install tool 380000249 (1) in the bevel drive-differential housing, complete with outer bearing rings, differential bearings adjustment shim, circlip and differential housing caps.

Screw the cones (3) of tool 380000249 (1) in or out to position the micrometer shaft to contact the inner bearing ring and eliminate end float between the cones and the outer rings of the differential bearings.

Adjust the micrometer so that the shaft is in contact with the inner bearing ring and measure the distance (H3).

Determine the corrected nominal distance (H5) between the ring gear axis and the large pinion inner bearing ring by adding or subtracting the correction value (C) stamped on the pinion preceeded by a + or - sign (if other than 0).

24588

H5 = H4 ± C 5

The thickness of the adjustment shim(s) is determined by subtracting the corrected nominal distance (H5) from the distance measured (H3). S = H3 - H5

SECTION 25 -- MFD AXLE -- CHAPTER 1 Example 1: --

Distance measured using micrometer H3 = 118 mm.

Nominal distance between ring gear axis and large diameter base of pinion H4 = 115 mm.

Correction value C = +0.2 mm.

Corrected nominal distance H4 + C = H5 (115 + 0.2 = 115.2)

Thickness of adjustment shim H3 - H5 = S (118 - 115.2 = 2.8 mm)

Example 2: --

Distance measured using micrometer H3 = 118 mm.

Nominal distance between ring gear axis and large diameter base of pinion H4 = 115 mm.

Correction value C = -0.2 mm.

Corrected nominal distance H4 - C = H5 (115 - 0.2 = 114.8)

Thickness of adjustment shim H3 - H5 = S (118 - 114.8 = 3.2 mm)

Example 3: --

Distance measured using micrometer H3 = 118 mm.

Nominal distance between ring gear axis and large diameter base of pinion H4 = 115 mm.

Correction value C = 0.00 mm.

Corrected nominal distance H4 Âą C = H5 (115 + 0.00 = 115 mm)

Thickness of adjustment shim H3 - H5 = S (118 - 115 = 3 mm)

SECTION 25 -- MFD AXLE -- CHAPTER 1

Pinion Shaft Installations 1. Install the bevel pinion with all parts (less the seal but including shims (S1 and S2, page 8) in the differential carrier. Shim sizes to be as determined in previous procedures. 2. Fit pinion retaining tool 380000257. 3. Insert wrench 380000268 on the adjuster ring nut. 4. Using the torque wrench on the pinion retaining wrench, hold the bevel pinion in position and, using a torque wrench positioned exactly as in fig. 64 on the ring nut wrench, tighten the ring nut (C1) to a torque value of 294 N⋅m (216.84352 ft-lb) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly.

24590

5. With torque wrench 380001633 (1) fitted on pinion retaining wrench 380000257 (2), check that the pinion rolling torque, without oil seal and relative dust seal, is 0.5 to 1 N⋅m (0.3688 to 0.7376 ft-lb). If the rolling torque is less than the prescribed value, fit a thinner adjustment shim (S1, page 8); on the contrary, if the torque is greater than the prescribed value, fit a thicker adjustment shim. 6. Unscrew the ring nut and fit the seal and the relative dust seal ring. Tighten the nut to a torque value of 294 N⋅m (216.84352 ft-lb) while simultaneously rotating the pinion shaft to ensure that the bearings are seated correctly. 7. 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 0.5 to 1.0 N⋅m (4.4 to 8.8 in-lb). Finally, secure the ring nut and fit the circlip on the bevel pinion shaft.

TRE0428A

SECTION 25 -- MFD AXLE -- CHAPTER 1

Differential Installation and Backlash Adjustment Proceed as follows: 1. Install the differential assembly (2) complete with bearings, adjustment shim (1) and relative circlip in the bevel drive-differential housing.

66 2. Install the differential support caps and the ring nut (2). Tighten the relative bolts (1) to a torque value of 59 N⋅m (43 ft-lb), then loosen and retighten to a torque of 20 N⋅m (14 ft-lbs).

67 3. With the bearings perfectly lubricated, rotate ring gear and, at the same time, tighten the ring nut using wrench 380000253 (1) to a torque value of 39 to 59 N⋅m (28 to 43 ft-lbs) to take up the axial play between the components. 4. Measure the backlash between pinion and ring gear, using a 1/100 dial gauge at a right angle to the outer edge of a tooth on the ring gear.

SECTION 25 -- MFD AXLE -- CHAPTER 1

5. Repeat the measurement in two positions 120° apart and compare the average of the three values (Gm) with the specified normal backlash: 0.15 to 0.20 mm (0.006 to 0.008 in).

If the backlash value is not within specifications unscrew one of the ring nuts, while tightening the other to an equal amount, so as to reset the prescribed clearance of 0.15 to 0.2 mm (0.006 to 0.008 in).

24593

69 Differential Bearing Pre-load Adjustment 1. Using wrench 380000253 (1) turn the adjustment ring nut and check using a torque wrench (2), the rolling resistance torque of the differential, as measured in the same conditions used to check the pinion, is : A2 = A1 + 1 to 1.5 N⋅m (8.8 to 13 in-lb) where: A2 = pinion differential rolling resistance torque:

24587

A1 = rolling resistance torque of pinion shaft as previously measured in step 7, page 34. NOTE: 1 to 1.5 N⋅m (8.8 to 13 in-lb) = rolling resistance torque of differential only. 2. Tighten the cap bolts (1) to a torque value of 113 N⋅m (83 ft-lb). 3. Install the safety plate, screwing the adjustment ring nut in or out, to reach the nearest notch. 4. Attach the bevel drive-differential to the axle casing after having carefully cleaned and degreased the mating surfaces and apply sealing compound [approx. 2 mm (0.078 ins)] along the marked line shown in the figure. 71

SECTION 25 -- MFD AXLE -- CHAPTER 1

SEALING COMPOUND APPLICATION The types of sealing compound to use are listed in Section 00.

SECTION 25 -- MFD AXLE -- CHAPTER 1

TOE-IN ADJUSTMENT When travelling forward in a straight path, the wheels of four-wheel drive tractors must be parallel to the longitudinal axis of the tractor, alternatively a slight toe-in of the front wheels is permissible up to a maximum of 6 mm (.23 ins) as measured at the edges of the wheel rims. To check the exact value of the toe-in setting of fourwheel drive tractors, proceed as follows. 1. Inflate the front tires to the prescribed pressure. 2. Position the steering at the straight ahead position (along the longitudinal axis of the tractor). 3. Check that the wheels are parallel to the longitudinal axis of the tractor. 4. Make a chalk mark on the front inside edges of both wheel rims, at the height of the wheel hub centers. Measure the distance (1) between the chalk marks.

5. Move the tractor forward to turn both front wheels through 180o. The chalk marks will now be measure between the rear inside edges of the wheel rims at the height of the wheel hub centers. Now measure the distance (2) checking that this new measurement is equal to or greater than the distance (1) by a maximum or 6 mm (.23 ins). The rotation of the wheels through 180o is necessary to eliminate the effect of wear, misalignment or distortion of the wheel rims on the measurements obtained.

24666

6. If it is necessary to correct the wheel alignment, remove nut (2) and pull the track rod end (1) out of its housing. Loosen locknut (3) and screw the track rod end (1) in or out to increase or decrease the distance (2) fig. 71. Reposition the track rod end (1) in its housing and re-check alignment as described in points 4 and 5 above. After having adjusted the alignment to within the prescribed limits, tighten locknut (3) to a torque of 180 Nâ&#x2039;&#x2026;m (132 ft-lbs) and nut (2) to 100 Nâ&#x2039;&#x2026;m (73 ft-lbs).

3 2 24667

NOTE: The self-locking nut (2) must be replaced each time it is removed or partially unscrewed.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

SECTION 27 -- REAR TRANSMISSION Chapter 1 -- Rear Axle and Transmission CONTENT Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Pinion and Differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Final Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Rear Axle Transmission -- Gearbox Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Transmission-Gearbox Case . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Gearbox Driving Shaft Axial Clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Differential Lock Engagement Sleeve Position Adjustment . . . . . . . . . . . . . . . . . . . . . . 39 Pinion Shaft Positioning Adjustment Ring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Pinion Shaft Pre-Load Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Differential Bearings and Backlash of Ring and Pinion Teeth . . . . . . . . . . . . . . . . . . . . 43 Differential Planetary and Side Gear Backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Final Drive Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly (Cover) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Disassembly (Housing) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 SPECIFICATIONS

PINION AND DIFFERENTIAL TD80D Pinion gear ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Clearance between sides of pinion pair teeth

TD95D

9/43 = 1:4.8 (30 kph) 11/43 = 1:3.9 (40 kph) mm (ins)

0.18 -- 0.23 (0.007 -- 0.009)

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

with two planetary gears

Mechanical differential lock control . . . . . . . . . . . . . . . . . . . . .

by means of pedal

Differential release control for mechanically controlled differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

controlled by service brake pedals

Planetary gear internal seat diameter . . . . . . . . . . . . . . . . . .

mm (ins) 25.040 -- 25.061 28.040 -- 28.061 (0.985 -- 0.986) (1.103 -- 1.104)

Planetary gear pin diameter

mm (ins) 24.939 -- 24.960 27.939 -- 27.960 (0.981 -- 0.982) (1.099 -- 1.100)

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

Clearance between planetary gears and their pins . . . . . . . Diameter of side gear hub seats on differential box . . . . . .

mm (ins)

0.080 -- 0.122 (0.003 -- 0.005)

mm (ins) 44.080 -- 44.119 (1.735 -- 1.736)

0.080 -- 0.122 (0.003 -- 0.005) 51.100 -- 51.146 (2.011 -- 2.013)

Diameter of side gear hubs . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (ins) 43.961 -- 44.000 50.954 -- 51.000 (1.730 -- 1.732) (2.006 -- 2.007)

Clearance between side gears and their seats . . . . . . . . . . .

mm (ins)

Pinion shaft positioning adjustment . . . . . . . . . . . . . . . . . . . . Adjuster shims for pinion shaft positioning . . . . . . . . . . . . . . .

Adjusting differential/pinion bearings . . . . . . . . . . . . . . . . . . .

0.080 -- 0.158 (0.003 -- 0.006)

0.100 -- 0.192 (0.004 -- 0.007)

see pages 37 and 38 mm (ins)

1.85 -- 1.90 -- 1.95 -- 2.00 -- 2.05 -2.10 -- 2.15 -- 2.20 -- 2.40 -- 2.45 -2.50 -- 2.55 -- 2.60 -- 2.65 -- 2.70 (0.072 -- 0.074 -- 0.076 -- 0.078 -0.080 -- 0.082 -- 0.084 -- 0.086 -0.094 -- 0.096 -- 0.098 -- 0.100 -0.102 -- 0.104 -- 0.106) see page 43 (see over)

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

3 (cont.)

TD80D Adjusting differential bearings and pinion coupling clearance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TD95D

see applicable section

Differential pinion and side gear backlash . . . . . . . . . . . . . . .

mm (ins)

Thickness of differential side gear clearance adjustment shims

mm (ins)

Thickness of differential pinion thrust bearings . . . . . . . . . . .

mm (ins)

0.15 (0.006)

0.18 (0.007)

1.5--1.6 (0.059 -- 0.062) 1.47--1.53 (0.057 -- 0.060)

Adjusting clearance between pinion and side gear teeth . .

see applicable section

Adjusting differential lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see applicable section

Differential lock control fork adjuster shim . . . . . . . . . . . . . . .

mm (ins)

0.5 (0.019)

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

mm (ins)

220 (8.66)

-- length of spring under load of 177--195 N (40 -- 44 lbs) .

mm (ins)

157.5 (6.2)

Spring for differential lock control fork :

FINAL DRIVES TD80D Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

pinion type and spur gears 11:67=1:6.1

Reduction ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TD95D

11:68=1:6.2

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 TORQUE TORQUES Torque settings PART TO BE TIGHTENED

Thread Nm

ft lb

Retaining bolts for rear transmission/gearbox upper cover (C1) . . .

M 10 x 1.25

Bolts for securing lift to rear transmission box (C2) . . . . . . . . . . . .

M 12 x 1.25

Bolts for securing PTO box to transmission / gearbox case (C3)

M 16 x 1.5

221

163

Bolts for securing torsion bar to transmission / gearbox case (C4)

M 16 x 1.5

221

163

Nuts for stud bolt securing final drive box to transmission / gearbox case (C5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

Drive wheel hub to disc retaining nuts (C6) . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

255

188

Drive wheel rim to disc retaining nuts (C7) . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

245

188

Ring bevel gear retaining bolts (C8) . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

123

Bevel drive -- differential support retaining self--locking bolts (C9)

M 10 x 1.25

Final drive casing cover retaining bolts (C10) . . . . . . . . . . . . . . . . .

M 10 x 1.25

Drive wheel axle retaining nut (C11) . . . . . . . . . . . . . . . . . . . . . . . . .

M42 x 1.5 M 55 x 1.5 M 60 x 2

491 882 882

362 650 650

Differential lock pedal support retaining bolts . . . . . . . . . . . . . . . . .

M 10 x 1.25

Nuts for drive wheel ballast ring retaining bolts . . . . . . . . . . . . . . .

M 14 x 1.5

Nut for driver gear shaft (C12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 32 x 1.5

294

217

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

C1 59 Nm

C2 98 Nm

C12 294 Nm C3 221 Nm

C4 221 Nm C9 59 Nm C7 245 Nm

C6 255Nm C8 123 Nm C5 98 Nm C11 882 Nm

C10 59 Nm TRE0550A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 SPECIAL TOOLS

WARNING The operations described in this Section must be performed only with the ESSENTIAL tools marked with (X). To work in complete safety and to ensure optimal technical results with a minimum of time and effort, they must be supplemented by the special tools recommended below and with those to be specially constructed by you and for which the construction diagrams are given in this manual. List of special tools required for the various operations described in this Section : 380000236 Trolley for tractor disassembly.

Hook for lifting clutch box. Rotating stand for overhaul. Rear mounting (with 380000301). Front mounting (with 380000301). Adapter for extracting bevel pinion (with 380000549). 380000549 Slide hammer. 380000249 Bevel pinion positioning gauge. 50006 Punch for removing gearbox drive shaft (see page 4, Sect.21, Chapter 1). 50007 Tool for adjusting gearbox drive shaft (see page 4, Section 21, Chapter 1).

380000277 380000301 380000271 380000272 X 380000838

2 Tool to make for bevel pinion extraction (Mark part with No. 50144 -- Measurements in mm) Make in UNI C40 material. Spring pin 3 x 20 mm.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

3 Tool to make for adjusting the bevel drive (engrave number 50027 on the tool -- measurements in mm) Make in Fe 42 C material.

26259

4 Tool to make for adjusting the assembly position of the bevel pinion shaft (Mark tool with no. 50004 -- Measurements in mm) Make using Aq 45 material.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 DESCRIPTION AND OPERATION

The rear transmission transmits power from the gearbox to the lateral final drives by means of the pinion. The pinion is of the helical tooth type and is supported by taper--roller bearings. The differential has two planetary gears and is equipped with a mechanically controlled differential lock.

Final drives are of the pinion type and are controlled by the pinion output half--shafts, the same shafts that control the service brakes. When the differential lock is not needed, it is kept disengaged by spring, which exerts a force on fork.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

SECTIONAL VIEWS

TRE0551A

5 Cross--sectional views of transmission--gearbox case 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Mid--range and reverse gear shift rail. Slow and fast gear shift rail. 1st and 2nd gear shift rail. Poppet balls. Spring for ball (4). Gear engagement safety pawl. Spring for ball (8). Poppet ball. 3rd and 4th gear shift rail. PTO external control lever. Gear engagement safety pawl. Plug. Range engagement safety pawl.

14. 15. 16. 17. 18. 19. 20. 21. 22.

Plug. Reverse gear support pin. Retaining bolt. Reverse idler gear. Thrust bearing. Snap ring. PTO shaft. Reverser drive shaft. Engagement gear for mid--range and reverse gears. 23. Driving gear for mid--range gears. 24. Snap ring.

Note -- Screw on plugs 12 and 14 using one of the sealing compounds listed in Sect. 00.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 Cross--sectional view of final drive

C10. Final drive housing cover cap screws C5. Cap screws securing final drive housing to transmission housing C7. Nuts securing disc to wheel rim C13. Cap screws securing disc to wheel hub C11. Nut T Drain plug 1. Wheel disc 2. Wheel shaft 3. Final drive housing cover 4,5. Ball bearings 6. Roller bearing 7. Ball bearing 8. Final drive driven gear 9. Axle shaft 10. Final drive casing 11,12.Seals 13. Seal guard 14,15,16. Retaining rings 17. Seal thrust ring 18. Grease nipple 19. Lock washer 20. Seal

C7 3

14 7

16 4 C 13 17

13 2

5 C11

18 1

12 C10

T TRE0552A

6 NOTE: During installation, apply sealing compound to surfaces X as shown in Section 00, Chapter 1, page 1.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

38 TRE0554A

7 C1. C2. S. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Longitudinal and Cross Sectional Views of Pinion and Differential Unit 15. Pinion shaft Ring gear retaining screw 16. PTO shaft Differential support retaining screw 17. PTO control sleeve Pinion shaft positioning shim 18. Fork Differential support 19. Differential lock shaft Differential support 20. Range gear retaining ring Taper roller bearing 21. Pinion securing plate Taper roller bearing 22. Differential bearing ring nut Differential lock sleeve 33. Reverse driven gear Ring gear 34. Driven gear for slow speed gears (low range) Side gear 35. Engagement sleeve for slow and fast speed Side gear gears Planetary gears 36. Transmission driven shaft ring Planetary gears shaft 37. Retaining half--ring Planetary gear shaft retaining screw 38. Lock ring Side gear shim Planetary gear shim Differential box

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

TROUBLESHOOTING PINION AND DIFFERENTIAL Problems

Possible causes

Solutions

Transmission noisy while the trac- Incorrect adjustment of bevel pin- Remove the rear transmission box tor is moving, even when the gear- ion and / or ring gear bearings. and adjust the pinion and ring gear box is in neutral (not arising from bearings correctly. final drives). Transmission noisy when tractor Excessive clearance between pin- Remove the rear transmission box loaded and unloaded. and correctly adjust the pinion and ion and ring gear teeth. ring gear bearings. Differential repeats noise within An internal component broken or Remove the rear transmission box, short intervals. replace the worn parts and correctly defective. adjust the differential gear clearance. Transmission noisy and assembly Pinion and / or differential bearing Remove the rear transmission box overheats. and correctly adjust the pinion and clearances insufficient. ring gear bearings. Insufficient coupling clearance be- Remove the rear transmission box tween the teeth of the pinion and and correctly adjust the ring gear bearings. the ring gear.

FINAL DRIVES Problems

Possible causes

Solutions

Final drives make noise when An internal component broken or Remove the final drive box and retractor is moving, even with the defective. place the damaged parts. gearbox in neutral neutral.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

OVERHAUL REAR AXLE TRANSMISSION -- GEARBOX CASE Removal Related service instructions up to item 44, (see pages from 11 to 21) guides also removal operations of suspended platform with the exception of heating pipes and air condition components removal.

WARNING Lift and handle all heavy parts using proper equipment of adequate lifting capacity. Make sure that the assemblies and parts are supported by appropriate tools and hooks. Make sure that no person is standing in the vicinity of the load to be lifted. To remove the body, proceed as follows : 1. Disconnect the negative terminal of the battery. Remove the plug of rear transmission (1) and gearbox (2) and drain the oil into suitable containers.

TRE0209A

7 2. Remove the drain plug from the 4WD transfer box (1) and drain the oil into a suitable container.

TRE0564A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

3. Place the tractor dismantling stand 380000236, so that the fixed support (1) is under the rear transmission case in the area of the engine coupling flange and the mobile support (2) under the engine in the area of the flange attached to the gearbox case.

25050

9 4. Place another mobile stand 380000236 under the front ballast carrier to prevent any possibility of the engine turning and tipping forwards when the gearbox case is removed. Put wooden chocks (1) between the stands and the tractor body. Turn the stand height adjustment lever to bring the chocks (1) into contact with the tractor.

25051

10 5. Remove electrical connections (1) extending to the dashboard.

TREO185A

11 6. Remove the socket (1) with its cable that passes from the instrument panel and over the gearbox to the rear fender.

TRE0216A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

7. Remove the support bolt (1) from the injection pump and disconnect the hand and foot throttle cables.

TRE0177A

8. After draining the oil from the power steering reservoir, disconnect the flexible hoses (1) from the hydrostatic steering pump. Mark the hoses, before removal, to facilitate installation in the correct position.

TRE0160A

14 9. Disconnect the angle drive cable from its adapter (1) and remove the retaining bolt (2).

TRE0501A

10. Remove the filtering line (1) and pressure pipe (2) of hydraulic pump.

TRE0210A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

11. Loosen the clamp (1) and remove the cab heating inlet hose.

TRE0178A

12. Loosen the clamps (1) and remove the cab heating outlet pipes (2) (It is suggested to mark them before removal).

TRE0204E

18 13. Remove the wing nut (1) securing the condenser (2).

25413

19 14. Remove the compressor retaining bolts (1) and take out the earth connection.

24904

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 15. Move the disconnected compressor (1), condenser (2), figure 19 and filter/dryer onto platform together with flexible hoses and valves.

17 1

TRE5001A

21 16. Take out the rubber floor mat of the platform, and then remove the surrounding bolts (1) securing engine--clutch assembly to the gearbox--rear transmission case.

TRE0199A

17. Place a hydraulic jack (1) underneath the middle of the fuel tank (2) and lift it as required.

TRE0502A

23 18. Unscrew the plug (1) by allen key and drain the fuel tank using suitable container. Choose a container taking into consideration the tank capacity is 90L (24 gallons).

TRE0181A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

19. Remove the bolts (1 and 2) securing the fuel tank to the foot step.

TRE0049A

20. Remove the bolts (1 and 2) from the steel support bracket underneath the fuel tank.

TRE0206A

21. Remove the screws and then remove the sheet metal protector (1) from beneath the fuel tank.

TRE0202A

27 22. Rest the front edge of the fuel tank on the ground.

TRE0211A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

23. Loosen the clamps and remove the inlet (1) and return (2) pipes of fuel tank. Remove the fuel tank completely.

TRE0201A

24. Remove the pin (1) and remove the clutch pedal cable from the upper surface of the cab/platform.

TRE0222A

25. Remove the nut (1) from the parking brake control cable. Remove the slave cylinder pipes (2) on both sides.

1 2

TRE0194A

31 26. Remove the retaining pin (1) and disengage the PTO clutch cable.

TRE0198A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

27. Remove the retaining pin (1) of 4WD engagement lever and remove the lever. 1

TRE0040B

33 28. Remove the pin from the mechanical differential lock pedal and take off the pedal head (1).

1 TRE0240A

34 29. Pull up the plastic boot, remove the retaining bolt (1) and remove the reverser control lever.

TRE0180A

30. Remove the retaining bolts (1) and remove the gear and range gear selection levers.

TRE0179A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

31. Remove the indicator and light connections (1) on both sides of tractor.

TRE0192A

37 32. Disconnect the retaining bolts (1) of seven--pole socket electrical connection and remove the earth cable bolt (2).

TRE0503A

38 33. Remove the retaining pins (1) and take out the auxiliary hydraulic valve control rods. 1

TRE0504A

34. Disconnect the auxiliary valve nuts (1) from their pipes.

TRE0200A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

35. Remove the split pins (1) and respective draft and position control levers.

TRE0505A

41 36. Remove the fast raise/lower control cable (1) from the lever and from its mounting (2).

24936

42 37. Remove retaining pin (2) from the bottom, and support bracket bolts (1) on the top of the hydraulic lift control rod. Remove the left and right lift rods.

TRE0205A

43 38. Remove the bolt (1) that secures the gearbox breather pipe clamp coupling.

TRE0126A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 39. Remove the bolt (1) that secures each side of the platform front supports.

TRE0506A

45 40. Remove four bolts (1) that secure the rear of the platform to the final drive.

TRE0193A

46 41. Attach the lifting bar to the lifting rings on the left and right side of the cab roof. Take necessary precautions to prevent damaging the structure. Use supports as required. Raise the cab slightly and verify that all components that would restrict the cab from being attached, have been removed. If satisfactory, complete the lifting operation.

TRE0157A

47 42. Attach two hooks to the signal support bar at the front and clamp the tool to the roll--bar at rear.

TRE0190A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

43. Remove the FWD shaft guard from its front (1), middle (2) and rear retaining bolts.

TRE0207A

49 44. Remove the snap ring (2) and withdraw the sleeve (1) from DT transfer box in the direction of the arrow.

25039

50 45. Remove the snap ring (2) and withdraw the sleeve (1) from the DT transfer box in the direction of the arrow.

25040

51 46. Remove the middle support bolts (1) from drive shaft and remove the shaft complete with support.

25041

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

47. Disconnect the trailer brake pump inlet pipes (1 and 2) from the transmission--gearbox case. Remove the coupling of the trailer brake control valve supply pipe (3).

TRE0507A

53 48. Remove the retaining bolts (1) together with the trailer brake valve assembly, after trailer brake control pipe removal.

TRE0507A

54 49. Disconnect the trailer brake control pipe (1) and the auxiliary valve pipes from the support plate (2).

25537

50. Connect a chain to a final drive assembly and remove it from the transmission--gearbox case. Repeat on the opposite side.

TRE0188A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

51. Remove the retaining bolts and lift the hydraulic body using the hoist.

TRE0187A

52. Use a chain to attach the tow hook and PTO to the hoist. Remove the three retaining bolts (1) for both side and remove the unit from rear transmission--gearbox case.

58 53. Unscrew the nut (1) and remove the bolt. Remove the right--hand lower link (3) and its spacer (2). Repeat on the left--hand lower link.

25773

2 59

54. Attach a belt to both the ends of the torsion bar (1). Ensure that belt is strong enough to lift the assembly. Remove the retaining bolts (2) and take off the assembly.

2 TRE0508A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

55. Remove the bolts, and then lift the gearbox cover (1).

TRE0104A

56. Unscrew the bolt (1) and remove the internal oil tank (2) from the transmission case.

25774

62 57. Connect the rear transmission--gearbox case to the hoist by chain. Remove the rear transmission--gearbox case using stand 380000236.

TRE0189A

TRE0553A

Diagram for application of sealing compound for rear transmission--gearbox case

28 SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 Installation

WARNING

18. Install the FWD drive shaft and secure it by means of the middle support and, the front and rear sleeves.

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

19. Install the guard onto transfer box shaft.

1. For the correct orientation of the various parts, refer to the illustrations on pages 5, 7, and 8.

21. Set the cab on the transmission box and secure using the retaining bolts.

2. Before installing boxes, supports and covers, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of about 2 mm (.078 in) diameter as shown in the diagram on page 28.

22. Connect the fast raise/lower control cable.

3. Apply the torque settings given on page 4.

25. Install the gearbox and final drive control levers.

4. Using the stand 380000236, install the rear transmission--gearbox case onto the clutch box.

26. Install the reverser control lever.

5. Install the flexion bar support complete with internal connecting rod. 6. Position the left and right brake friction discs. Install the brake assembly, and the lateral final drive assembly. 7. Install the PTO cover to the transmission--gearbox case. 8. Install the internal tank complete with oil discharge pipe. 9. Install the lower arms and spacers. 10. Install the tow hook. 11. Install the hydraulic lift complete. 12. Insert the springs and poppet balls and install the gearbox and final drive control rod support cover on the rear transmission--gearbox case. 13. Install and connect the lift control and oil filling pipes. 14. Install the third--point linkage support together with the quick--release installing support plate and electrical power sockets with respective connections. 15. Install the trailer brake valve complete with hydraulic valves. Install and connect the auxiliary hydraulic valve and trailer brake valve pipes. 16. Install and connect all the hydraulic pump inlet and outlet pipes and the connection pipes of the auxiliary hydraulic valves, hydraulic lift, FWD transfer box, etc. 17. Install the rear wheels and remove stand 380000326.

20. Screw on the rear transmission--gearbox case oil discharge plugs and the fuel tank discharge plug.

23. Connect the differential lock mechanical control rod. 24. Connect the parking brake control cable.

27. Connect the PTO speed selection cable. 28. Connect the synchronized PTO control lever. 29. Connect the auxiliary hydraulic valve control levers. 30. Install the fuel tank together with fixing brackets, mountings and rear transmission--gearbox breather pipes. 31. Connect the pipes and connections to the fuel tank. 32. Install and secure the compressor, the condenser and the filter / dryer. 33. Connect and secure the heater control pipes. 34. Connect the gearbox clutch control rod. 35. Connect the front service brake feeding and control pipes. 36. Connect the accelerator control cable. 37. Make all electrical socket connections between the cab and the tractor body. 38. Screw on the engine cooling liquid discharge plug on the base. 39. Fill up the fuel tank, the rear transmission--gearbox case and cooling circuit; prescribed products and their quantities are given in Sect. 00. 40. Connect up the front headlights. 41. Screw on the engine cooling liquid discharge plug on the base. 42. Fill up the fuel tank, the rear transmission--gearbox case and the cooling circuit; the prescribed products and quantities are given in Sect. 00. 43. Connect the negative terminal of the battery.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

TRANSMISSION--GEARBOX CASE Disassembly

WARNING Handle all parts with great care. Never place your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear. 1. Secure the transmission box--gearbox to the turning stand 380000301 using the front 380000272 and rear 380000271 mountings.

TRE0509A

65 2. Turn the box by 180Â°, undo the bolts (1) and remove the transfer box (2).

TRE0510A

66 3. Turn the box by 180Â°, then use a punch to remove the elastic pins (1) and take out the shift rails, the prongs, the gearbox and final drive control forks.

25783

67 4. Use a punch to remove the elastic pin (2) retaining the differential lock engagement fork (1). Withdraw the rod (4) and remove the helical spring (3) and the fork.

TRE0511A

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

5. Unscrew the lock rings of the differential support bearing pre--load ring nuts (2) and slightly slacken the ring nuts. 6. Unscrew the differential support retaining bolts (1), retrieve the supports and then remove the entire differential bevel crown wheel assembly from the rear of the casing.

27300

69 7. Remove the elastic pin (2) and take out the external lever (1) that controls the PTO synchronized with the gearbox.

2 TRE0512A

70 8. Withdraw the internal lever (2) complete with spring (1) and slide (3).

25791

71 9. Straighten out the notches and undo the driven shaft locking nut (1).

25792

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

10. Remove from the rear the snap ring (1) that retains the final drive driving shaft bearing.

25793

11. Using a hammer and a brass punch (1) withdraw the gear (2) for the mid--range speeds together with the respective bearings and engagement sleeve (3).

25794

74 12. Withdraw the final drive driving shaft (1).

25795

75 13. Remove the snap ring (1) that holds the bearing (2) onto the gearbox drive shaft.

25796

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 14. Install the tool 50006 (2) (see Sect. 21) onto the driving shaft and use the extractor (1) to withdraw the driving shaft. Remove the bearings, gears and respective bushings.

25797

15. Straighten out the notches in the washer that retains nut (1) and slacken the nut.

25799

78 16. Screw the adapter 380000838 (2) onto the pinion (3) and use the extractor with sliding weight 380000549 (1) to move the pinion by a few millimeters in the direction shown.

25901

79 17. Move the engagement sleeve (1) until it is possible to gain access with pliers (2) to remove the retaining snap ring.

25800

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

18. Move the gear (1) in the direction shown and remove the two retaining half--rings (2). Undo the nut (3) completely and withdraw the pinion, removing all parts.

25902

19. Undo the bolts (3), take out the support plate (1) and remove the bearing (2).

2 3

25903

20. Use a brass punch (2) and a hammer to move the driven shaft (1), withdraw the shaft and remove all the parts.

21. Mount the rear transmission--gearbox case by following sectional views and instructions given. 22. Apply the torque settings listed on page 4.

25904

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

Assembly

WARNING

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

1. Position the box vertically, insert the gearbox driven shaft gear set (2) and insert the shaft (1).

25907

84 2. Turn the box by 90Â°, install the front bearing (1) and the nut (2) and tighten to the prescribed torque as stated in Torque Table (C12).

25908

85 3. Install the bearing (2) in its housing on the box (front end) and lock it using the plate (1).

25903

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

4. Insert the gear shift forks (1 and 3) on the sliding rings (2 and 4) of the synchronizers.

5. Install the pinion shaft complete with all the parts and carry out the adjustments given on pages 38 through 42.

3 4

25912

87 6. Install the gearbox drive shaft complete with all parts and the adjuster shim, then position the bearing (2) and lock it using the snap ring (1).

25796

88 7. Insert the final drive driving shaft from the rear end, install the bearing (2) into its seat and lock using the snap ring (1).

25913

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 8. Install the lever (1) that controls the PTO synchronized with the gearbox, complete with spring, pawl and external lever.

9. Install the ring gear complete with support and adjuster shims (see adjustments on preceding pages). 10. Install the differential lock engagement control fork complete with spring--rod unit, external plate and the corresponding adjuster shims (see page 39).

25791

90 11. Install the piston and the corresponding differential lock control union. 12. Install all the rods, forks and gearbox and final drive control prongs. 13. Install the transfer box assembly.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

ADJUSTMENTS GEARBOX DRIVING SHAFT AXIAL CLEARANCE

WARNING

Use appropriate tools to align the holes. NEVER USE YOUR FINGERS OR HANDS. Proceed as follows : Note -- Once installed, the driving shaft gears must have an axial clearance of 0--0.25 mm (0 -- .009 ins). The bearings must therefore be adjusted to prevent them from being mounted with an axial preload. To perform this adjustment, it is recommended making a tool in the workshop according to the specifications given in the drawing in Sect. 21. 1. On the bench mount all the various components on the drive shaft, replacing the two rear bearings and the adjuster ring with the tool 50007 (1) (see Sect. 21).

2 H

2. Insert a screwdriver between the gear and its bushing and use a feeler gauge to measure the clearance (H).

3 25910

3. Measure the height (C) of the tool 50007 and the thickness of the internal rings of the two rear bearings (1 and 2). 4. The adjuster shim to be installed is given by : S = H + C -- A -- B where : H = measured clearance A and B = measured thickness of the bearings C = height of the tool. Example : -- measured clearance H = 1.3 mm (.051 ins) -- height of tool = 43.5 mm (1.712 ins) -- thickness of ball bearing (1) = 22.9 mm (.901 ins) -- thickness of roller bearing (2) = 18 mm (.708 ins) Thickness of adjuster ring : S = 1.3 + 43.5 -- 22.9 -- 18 = 3.9 mm (S = .051 + 1.712 -- .901 -- .708 = .154 ins) Note -- Since the gears are to be mounted with an axial clearance of 0--0.25 mm (0 -- .009 ins), in this case it will be necessary to install a shim (S) of 3.75 mm (.147 ins) so that to provide an axial clearance of: 3.9--3.75 = 0.15 mm (.154 -- .147 = .006 ins).

H 25911

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

DIFFERENTIAL LOCK ENGAGEMENT SLEEVE POSITION ADJUSTMENT

WARNING

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

Proceed as follows :

1. Mount the differential release device without the adjuster shim (S). 2. Fit the differential bevel crown wheel assembly on its supports. G. Clearance between differential lock sleeve and the right--hand bevel crown wheel bearing support. 0.5 รท 1.25 mm (0.0197 รท 0.0492 in.) All models C3.Lock pedal support retaining bolt. S. Differential lock sleeve travel adjuster shim. 1. Differential lock pedal. 2. Pedal support. 3. Fork control rod. 4. Fork. 5. Return spring. 6. Spring pin 7. Sliding Sleeve. 8. Differential support right--hand bearing.

TRE0514A

3. Check there is a clearance (G) between the sliding sleeve (7) of the differential lock and the right--hand support bearing of the differential (8) of: 0.5 รท 1.25 mm (0.0197 รท 0.0492 in.) that can be measured with the feeler gauge (T). 4. Adjust this clearance by varying the shims (S) fitted between the support (2) and the transmission casing. 94

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

PINION SHAFT POSITIONING ADJUSTMENT RING

Proceed as follows : 1. On the transmission--gearbox case mount the external ring of the bearing (1) with the test shim (2) and the external bearing ring (3, fig. 96).

25915

95 2. Position the bearing (2) on tool 50004 (figure 4), insert the bearing (3) and lock the tool (1).

1 2

25916

96 3. Position the tool 380000249 (2) with two conical parts in the differential supports and insert the micrometer (1) with depth rod into its seat and lock using the bolt.

25917

97 4. Screw down or unscrew the cones (1 and 2) so as to align the micrometer rod with the bearing. Adjust the cones (1 and 2) manually to lock the tool on the supports and eliminate any axial clearance.

1 H1

5. Move the depth rod of the micrometer into contact with the bearing and measure the value (H1).

25918

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

6. Calculate the corrected nominal distance (H3) between the ring gear axis and the major base of the pinion shaft : H3 = H2 + C where : H2 = 145.5 mm (5.728 ins). Nominal distance between the ring gear axis and major base of the pinion. C = Correction value stamped on the pinion, expressed in mm and preceded by a + or -- sign, if other than 0, to be added to or subtracted from the nominal distance (H2) respectively. 7. Thickness of the adjuster ring (S) is given by : S = H1 + Sp -- H3 where : H1

Sp =

Distance measured with the micrometer gauge. Corrected nominal distance between the ring gear axis and the major base of the pinion. Test ring.

Examples : Distance measured with the micrometer gauge H1 = 145.9 mm (5.744 ins). Thickness of test ring Sp = 1.90 mm (.074 ins). Nominal distance between the ring gear axis and major base of the pinion H2 = 145.5 mm (5.728 ins). a) Correction value C = + 0.2 mm (.0078 ins). Corrected nominal distance H3 = 145.5 + 0.2 = 145.7 mm (5.728 + .0078 = 5.736 ins). Thickness of adjuster ring : S = 145.9 + 1.90 -- 145.7 = 2.10 mm (S = 5.744 + .074 -- 5.736 = .082 ins). b) Correction value C = -- 0.2 mm (.0078 ins). Corrected nominal distance H3 = 145.5 -- 0.2 = 145.3 mm (H3 = 5.728 -- .0078 = 5.720 ins). Thickness of adjuster ring : S = 145.9 + 1.90 -- 145.3 = 2.50 mm (S = 5.744 + .074 -- 5.720 = .098 ins). c) Correction value C = 0 mm (0 ins). Corrected nominal distance H3 = H2 = 145.5 mm (5.728 ins). Thickness of adjuster ring : S = 145.9 + 1.90 -- 145.5 = 2.30 mm (S = 5.744 + .074 -- 5.728 = .090 ins). 8. Remove the tools 380000249 and 50004; take out the bearing external rings, the test shim and two differential supports.

1 H1

25918

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

PINION SHAFT PRE-LOAD ADJUSTMENT 1. Install the external bearing race together with the previously calculated adjuster shim (S) and the pinion complete with range gears.

2. Tighten the bearing adjustment nut (1) while turning the pinion shaft to allow the bearings to bed in until rolling torque of 0.73 -- 1.47 Nm (0.54 -- 1.08 ft-lb) is obtained.

25799

100 3. Engage low range gears. With a cord wrapped around the slow speed gear (low range) transmission on the pinion, make sure that the gearbox shafts are not turning (idle). The specified rolling torque corresponding to a force measured by the spring scale (1) should be 8.63 -- 17.2 N (1.94 -- 3.86 lb).

25919

101 4. After obtaining the recommended torque, bend the securing plate (1) onto adjuster nut to lock the nut in place.

TRE0516A

102

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

DIFFERENTIAL BEARING AND BACKLASH OF RING AND PINION TEETH Adjusting the ring bevel gear bearings and checking the clearance between the teeth of the bevel gear pair.

WARNING Handle all parts with great care. Never place your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

WARNING

Always use appropriate tools to align the holes. NEVER USE YOUR FINGERS OR HANDS. Proceed as follows : 1. With the bevel pinion fitted, insert the differential assembly complete with the bevel crown wheel. Secure the right-- and left--hand supports on the gearbox transmission casing and bring the relevant ring nuts into contact with the races of the bearings. 2. Using wrench 50027 (see page 7) slightly screw the right-hand ring nut (2) onto the support (1), and then do the same for the left-hand ring nut so as to obtain a slight pre--load on the bearings.

27300

103 3. Using a 1/100 dial gauge (1) measure the radial clearance on the sides of the bevel drive teeth (three measurements at 120o and arithmetic mean of the three readings, the difference between the three measurements must not exceed 0.05 mm) and compare the result with the nominal clearance: 0.18 -- 0.23 mm (0.0071 -- 0.0090 in.). We will initially be looking for a clearance of 0.18 mm (0.0071 in.).

TRE0518A

4. Setting high -- low backlash depends on the ratio between the decrease -- increase in clearance and the movement of the differential casing. As a result, the end displacement (Z) of the differential unit is: Z = (G--0.18) x 1.4 where: 1.4 = Ratio between decrease--increase in backlash and movement of the differential casing. G = bevel drive backlash, as previously measured. After calculating Z, proceed as follows: if Z < 0 move the crown wheel away from the pinion. if Z > 0 move the crown wheel nearer to the bevel pinion.

104

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

5. One complete turn of the ring nut corresponds to a 2 mm axial movement of the crown wheel. A 60Â° turn of the ring nut, equivalent to one side of the ring nut hexagon, corresponds to an axial movement of the ring nut of: Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.)

TRE0519A

105 6. Making the differential turn, unscrew the right-hand ring nut with tool 50027 (2) and tighten the left--hand ring nut (1) by the same amount if Z > 0, otherwise unscrew the left--hand ring nut (1) and tighten the right--hand ring nut by the same amount if Z < 0 in order to obtain a backlash initially of 0.18 mm.

Z = (60 : 360) x 2 = 0.33 mm (0.0130 in.) 7. On obtaining a clearance of 0.18 mm, tighten the right--hand ring nut to obtain a rolling torque of: 28118

106 Pinion rolling torque (range gears in neutral) ft lb

0.5421 to 1.0849

0.735 to 1.471

Pinion rolling torque measured on crown wheel (with bearings not pre--loaded) ft lb

2.8934 to 5.0634

Total rolling torque of pinion measured on crown wheel (with bearings not pre--loaded)

ft lb

3.923 to 6.865

torque measured on pinion + (0.7235 to 1.4463)

torque measured on pinion + (0.981 to 1.961)

Measuring Differential Bearing Pre-load with Spring Scale and Cord 8. Making sure you do not drive the shafts of the gearbox, it is possible to check the rolling torque with a spring scale (1) and a cord wound around the outer diameter of the differential casing, keeping to the values stated in the table:

TRE0517A

107

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

Differential casing ∅ 187 mm (7.3622 in.) Pinion rolling torque

Force of the pinion at the torque meter measured on the crown wheel (with bearings not pre-loaded)

Force of the pinion at the torque meter measured on the crown wheel (with bearings pre-loaded)

ft lb

0.5421 to 1.0849

0.735 to 1.471

9.4401 to 16.5201

41.97 to 73.45

Force on pinion + (2.36 to 4.72)

Force on pinion + (10.49 to 20.99)

Differential casing ∅ 206 mm (8.1102 in.)

Pinion rolling torque

Force of the pinion at the torque meter measured on the crown wheel (with bearings not pre-loaded)

Force of the pinion at the torque meter measured on the crown wheel (with bearings pre-loaded)

ft lb

0.5421 to 1.0849

0.735 to 1.471

8.5578 to 14.9982

38.05 to 66.68

Force on pinion + (2.1394 to 4.2789)

Force on pinion + (9.51 to 19.02)

9. Using a 1/100 dial gauge (1), check the clearance between the teeth of the bevel drive; if this backlash remains between 0.18 -- 0.23 mm (0.0071 -- 0.0090 in.) (0.21 mm (0.0083 in.) on average) fine, otherwise:

— if the backlash is any greater, use the wrench 50027 (1) to unscrew the right--hand ring nut and tighten the left--hand one by an equal amount. — if the backlash is any lower, unscrew the left--hand ring nut and tighten the right--hand one by an equal amount.

TRE0518A

108

NOTE: It is important to unscrew one ring nut and alternately tighten the opposite one by an equal amount so as not to change the bearing pre--load that has already been calculated. TRE0520A

109

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

10. Lock the right and left-hand ring nuts in position with the lock ring (1).

110

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

DIFFERENTIAL PLANETARY AND SIDE GEAR BACKLASH With the dismantled differential on the bench, proceed as follows :

IMPORTANT All parts of the differential must be cleaned so that oil residue does not effect the accuracy of the adjustment.

1. Mount the side gears (2) and (5) without rings (1) and (6) on the differential box. Insert the differential pinions (3) and (8) complete, with their related clearance rings and with the pin (7). Tighten the retaining bolt (4) by a few turns in order to prevent the pin from moving.

5 6

7 8 25920

111 2. Manipulate the RH side gear so that it comes into contact with the side pinion and, using a depth micrometer, measure the distance (H1), making two diametrically opposed measurements and taking the arithmetic mean of the two values measured.

H1 25921

112 3. Push the side gear so that it touches the differential casing and measure the distance (H2). 4. Repeat the same operations for the left--hand side gear.

25922

H2 113

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

5. Axial movement of each side gear (2) and (5) without shims is given as : Gs or Gd = H1 -- H2

5 6

where : Gs = axial movement of LH side gear; Gd = axial movement of RH side gear;

H1 and H2 = distances measured on LH or RH side gear (steps 2 and 3). The normal clearance envisaged between the sides of the pinion and side gear teeth is 0.18 mm (0.0071 in.). Bear in mind that the average ratio between the normal clearance of differential pinion--side gear and the equivalent axial movement of the side gears is 1--1.7. The axial movement of the side gears corresponding to the normal prescribed clearance between the teeth is 0.18 x 1.7 = 0.30 mm (0.0071 x 1.7 = 0.0118 in.). Thickness of the spacer rings (1) and (6) to be inserted on the differential box are : Ss = Gs -- 0.30 mm (0.0118 in.) (for LH side gear) Sd = Gd -- 0.30 mm (0.0118 in.) (for RH side gear) Available shims are 1.5 and 1.6 mm to use for the side gear as shown on page 2. Fit shims of the closest thickness for the LH and RH side gears according to calculations).

8 25920

114

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

FINAL DRIVE REMOVAL

WARNING Handle all parts with great care. Never place your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

WARNING Always use appropriate tools to align the holes. NEVER USE YOUR FINGERS OR HANDS.

CAUTION Raise and handle all heavy components using a suitable lift. Ensure that units or parts are supported by suitable slings or hooks. Ensure that there is no one in the vicinity of the load to be lifted

Remove the final drive as follows :

6. Drain oil from rear transmission and final drive housings. 7. Position a support stand under transmission housing and remove ROPS frame, wheels, fenders and platform. 8. Take out cap screws (C5) Fig.1, Page 5 and remove final drive assembly as shown at Fig.115.

TRE3011A

115 Disassembly (Cover) Remove the final drive as follows : 9. Take off cap screws (C10) Fig. 6, Page 10 and remove final drive cover (3) Fig. 6 with driven gear (8) Fig. 6.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

Driven gear retaining nut removal

Remove the gear retaining: 10. Tighten two M16 x 1,5 screws (C5) Fig. 116, into two of the wheel disc holes on hub and clamp wheel shaft in vice Fig. 116; 11. Unscrew nut (C5, Fig. 6, page 10) as shown in Fig. 116 with a suitable spanner (B). C5

TRE3012A

116

12. Withdraw driven gear (8). Fig. 6, page 10 from wheel shaft (2) using puller as shown in Fig. 117.

TRE3013A

117

Wheel shaft removal (installation) (Arrow indicates shaft removal direction.) 13. Knock out wheel shaft (2) by beating with lead hammer in the direction shown by arrow in Fig. 118.

14. Use puller to withdraw outer ring (7) from cover (3); 15. Finally, withdraw the bearing (4) from cover, having first removed retaining circlip (21). TRE3014A

118 Disassembly (housing) 16. Remove the bearing (5) from the housing (10) Fig. 119, with a suitable puller;

10 5

17. Remove retaining ring (17) Fig. 119, and withdraw axle shaft (9) Fig. 119, together with bearing (6) Fig. 119, in the direction shown by arrow.

6 9 7

TRE3015A

17 119

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1 18. Remove the roller bearing internal ring (7) Fig. 119, page 50, from the axle shaft, using puller separator as shown in Fig. 120, and the ball bearing (7) Fig. 6, page 10, from the axle shaft (9) Fig. 119, having first removed the lock ring;

19. Check and replace damaged and worn parts;

20. Check lip seals (11--12) Fig. 6, page 10, and replace if necessary; position as shown in Fig. 6.

TRE3016A

120 Assembly Carry out the above operations in the reverse order, bearing in mind the following: 21. Place the roller bearing (7) Fig. 118, outer ring in its seat in the final drive cover with mark on the outside; 22. Install the other bearings, using appropriate installers; 23. Fit the half shaft and wheel shaft, taking care not to damage the seals (11--12) Fig. 6; 24. Fit the roller bearing internal ring (7) Fig.119, page 50, on the half shaft (9) Fig. 119, having heated it in the oil to 80--90Â°C (176--194Â°F); 25. Tighten the gear locknut (C11) Fig. 1, page 5, using wrench (B) Fig. 116, page 50, previously used for disassembly. 26. Tighten all the nuts and screws to the torque values given on page 4. 27. Clean and grease the surfaces in contact between the housing (10) Fig. 6, page 10, and the cover (3) Fig. 6, page 10, inserting a new seal (20) Fig. 6, page 10; 28. Thoroughly clean and grease the surfaces (X) Fig. 65, page 28, applying jointing compound.

SECTION 27 -- REAR TRANSMISSION -- CHAPTER 1

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SECTION 31 - POWER TAKE-OFF Chapter 1 - Power Take-Off

CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Special Tools

................................................................ 4

Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation of Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Independent PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Ground Speed PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 PTO Speed Selector Lever . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Single Lever PTO Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Troubleshooting for Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 540 Mechanical PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 540 RPM PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 540/1000 RPM PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SPECIFICATIONS TD80D

TD95D

540 rpm PTO 1) Independent of tractor travel speed or: 2) Synchronized with gearbox

Type (Independent and ground speed PTO) . . . . . . . . . . . . .

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical by means of hand lever located on LH side of driverâ&#x20AC;&#x2122;s seat

Direction of rotation (viewed from rear of tractor) . . . . . . . . .

clockwise

Engine speed with PTO shaft rotating at 540 rev/min . . . . .

rev/min

2200

PTO speed with engine at maximum power (2500 rev/min)

rev/min

614

Ground speed PTO. Rear wheel speed with PTO shaft rotating at 540 rev/min (30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel speed rev/min

8.2

8.9

Ground speed PTO. Rear wheel speed with PTO shaft rotating at 540 rev/min (MFD 40 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel speed rev/min

6.73

7.25

Diameter of PTO shaft at position of bearings . . . . . . . . . . . mm (in) Diameter of PTO shaft at splined end . . . . . . . . . . . . . . . . . .

49.938 - 50.000 (1.9661 - 1.9685) 1-3/8 in (6-spline)

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

3 (continued)

2-speed 540/1000 rpm PTO (option - TD95D models) Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single-speed PTO

Engagement and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

as for single-speed PTO

Direction of rotation (viewed from rear of tractor) . . . . . . . . .

as for single-speed PTO

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

by means of hand lever located on rear RH side of driverâ&#x20AC;&#x2122;s seat

Engine speed with PTO shaft rotating at 540 rev/min . . . . .

rev/min

2200

Engine speed with PTO shaft rotating at 1000 rev/min . . . .

rev/min

2380

PTO speed with engine at maximum power (2500 rev/min): - for 540 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - for 1000 rev/min PTO . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev/min rev/min

614 1050

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 (continued) TD80D

TD95D

Ground speed PTO. Rear wheel speed with PTO shaft rotating at 540 rev/min (30 and 40 km/h versions) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel speed rev/min

Ground speed PTO. Rear wheel speed with PTO shaft rotating at 1000 rev/min (30 km/h version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel speed rev/min

14.1

15.2

Ground speed PTO. Rear wheel speed with PTO shaft rotating at 1000 rev/min (40 km/h FWD version) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

wheel speed rev/min

11.51

12.4

Diameter of PTO shaft at splined end: - 540 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . - 1000 rpm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

rev/min rev/min

as for single-speed PTO

1-3/8 in (6-spline) 1-3/8 in (21-spline)

External diameter of driven gear support bushings . . . . . . . mm (in)

49.925 - 49.950 (1.9655 - 1.9665)

Internal diameter of driven gears . . . . . . . . . . . . . . . . . . . . . . mm (in)

50.050 - 50.089 (1.9705 - 1.9720)

Clearance between driven gears . . . . . . . . . . . . . . . . . . . . . . mm (in)

0.100 - 0.164 (0.0039 - 0.0065)

Diameter of driven shaft at front and center bushings . . . . . mm (in)

39.166 -- 39.191 (1.5420 --1.5429)

Diameter of driven shaft at rear bushing . . . . . . . . . . . . . . . . mm (in)

34.984 -- 35.000 (1.3773 -- 1.3780)

Internal diameter of front and center bushing . . . . . . . . . . . . mm (in)

39.200 -- 39.239(1.5433 --1.5448)

Internal diameter of rear bushing . . . . . . . . . . . . . . . . . . . . . . mm (in)

35.009 -- 35.048 (1.3783 -- 1.3798)

Clearance between shaft and front and center bushings . . mm (in)

0.009 -- 0.073 (0.0004 -- 0.0029)

Clearance between shaft and rear bushing . . . . . . . . . . . . . . mm (in)

0.009 -- 0.064 (0.0004 -- 0.0029)

SPECIAL TOOLS Important - The operations described in this section must be performed solely with the ESSENTIAL tools marked below with (X). To work in complete safety and to ensure optimal technical results with a minimum of time and effort, they must however be supplemented with the specific tools recommended below and with those to be specially constructed by you and for which the construction diagrams are given in this manual.

380000227 Hook for lifting PTO 380001597 Guide pins for PTO unit 380000223 Installer for PTO driving shaft bearings

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

TIGHTENING TORQUES

C2 - 25 Nm

C1 - 221 Nm

C4 - 294 Nm Single-speed 540 rev/min PTO 26276

1 PART TO BE TORQUED

Thread

Bearing support fixing screws (2- and 3-speed PTO) . . . . . . . . . . . .

Torque setting Nâ&#x2039;&#x2026;m

ft-lbs

M 12 x 1.25

PTO box fixing screws (C1, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163

PTO guard fixing screws (C2, fig. 1) . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

M 32 x 1.5

294

217

Driven gear shaft lock nut: (C4, fig. 1) for single- or 2-speed PTO . . . . . . . . . . . . . . . . . . . . . . .

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SECTIONAL VIEWS

1 2

4 5 X

9 7 8

single-speed 540 rev/min PTO 26278

2 1. 2. 3. 4. 5.

Cross-sectional view of single speed PTO 6. Driven shaft lock nut 540 rev/min PTO cover 7. Snap ring Snap ring 8. Driven gear Driving gear 9. Snap ring 540 rpm PTO driven shaft PTO guard retaining screws

NOTE: When installing use sealing compound of the type shown in section 00 on surface X as shown above.

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

2 3 4 27 5 6 25 24

23 22 21

20 19

9 X

10 11

2-speed 540/1000 rev/min PTO 26278

12 3

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

Cross-sectional view of single- and 2-speed PTO 12. Rear transmission casing 540/1000 rev/min PTO cover 13. Rear transmission support PTO unit retaining screw 19. Driven gear support bushings Driving shaft bearings 20. Driven shaft lock nut Snap ring 21. Fixed gear Self-locking nut to secure splined shaft 22. Coupling sleeve 540 rev/min splined shaft 23. Driven gear for 1000 rev/min speed 1000 rev/min splined shaft 24. Driven gear for 540 rev/min speed Seal 25. Double driving gear Driven shaft bearings 27. Snap ring Cover centering pin

NOTE: When installing use sealing compound of the type shown in section 00 on surface X as shown above.

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

26278

4 Cross-sectional view of single- and 2-speed PTO 17. PTO speed selector lever 20. Rear cover 18. Roll pin 21. Fork 19. Shaft 22. O-ring

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

3 11

9 8

4 5 6

TRE0990A

5 Section views - 540 - 1000 rev/min PTO, not synchronized with gearbox, with speed selection by replacement of splined output shaft. 1. Splined 1-3/8 in output shaft (6 splines) for 540 rpm PTO, or 1-3/8 in output shaft (21 splines) for 6. Return spring 1000 rpm PTO 7. Return rod 2. Driven shaft 8. Speed selector lever support 3. Snap ring securing part 9. Speed selector lever 4. Speed selector rod 10. Speed selector sleeve 5. Speed selector sleeve control fork 11. Thrust washer

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

TRE0990A

6 Section view of rigid coupling sleeve for single lever PTO, not synchronized with gearbox. 1. PTO Coupling sleeve 2. Sleeve fixing circlip

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 DESCRIPTION AND OPERATION OF MECHANICAL PTO

11 2

The PTO, located at the rear of the tractor, transfers power to the implement being transported or towed. It can be controlled either directly from the engine clutch or from the gearbox clutch. The PTO is shown with the safety cap (1) and the guard (2) in position. The safety cap must be removed to couple up an implement to the PTO shaft. The PTO with mechanical engagement/disengagement is available in three versions:

26280

7 — single-speed PTO, 540 rev/min (standard) — two-speed PTO, 540/1000 rev/min (option). Independent PTO Proceed as follows: — with the PTO clutch disengaged, i.e. with the control lever (1) fig. 8, forward at position D; — move the PTO selector lever (1) fig. 9, to position B so as to engage the PTO sleeve (3) fig. 10, with the toothed coupling of the shaft (2) which is driven by the engine;

A D

— engage the PTO by slowly moving the lever (1) fig. 8 backward to position A.

When engaged, the PTO shaft rotates and the PTO warning lamp on the instrument panel lights up.

1 TRE0106A

In these conditions the operation of the PTO is completely independent of the travel of the tractor, so: — the tractor can be stopped without stopping the PTO; 1

— the PTO can be stopped without stopping the tractor (by disengaging the PTO clutch). To disengage the PTO move the PTO speed selector (1) to the central position E.

C E B TRE0043A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

Ground Speed PTO Proceed as follows: — keep the PTO clutch control lever (1) fig. 8, in position D; — fully depress the gearbox/engine clutch pedal; — wait briefly, then move the PTO speed selector (1) forward to position C and release the gearbox/engine clutch pedal; In these conditions the PTO coupling sleeve (3) fig. 10, is turned directly by the toothed coupling of gear (1) in the gearbox. When the tractor is stationary the PTO shaft does not turn. When changing from forward to reverse gear, the direction of rotation of the PTO shaft reverses.

NOTE: When the PTO is not being used, move the lever (1), to position E (the neutral position of the PTO engagement sleeve (3) fig. 10). 26281

10 PTO Speed Selector Lever (2) fig. 11 2

To change PTO speed, proceed as follows: — lift the spring-loaded collar (1) upwards; — move the lever (2) forward to position (3) to select 1000 rev/min PTO speed.

1 3

This activates the external control lever (17) fig. 4 by means of a tie-rod. The external control lever in turn rotates the internal fork device (21) and selects the PTO speed by means of the coupling sleeves. 11

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SINGLE LEVER PTO OPERATION To operate the power take-off, proceed as follows: --

disengage the power take-off clutch by moving the lever (1) fig. 12 to the UP position;

engage the clutch slowly by moving lever (1) fig.13 to DOWN position so as to start the splined output shaft turning.

In this case, operation is totally independent of the tractor ground speed, and you can therefore: --

stop the tractor without stopping the power take-off;

stop the power take-off without stopping the tractor (by disengaging the power take-off clutch).

The shaft rotates clockwise, as seen from the rear of the tractor. To disengage the power take-off, move the selector lever (1) fig.12 to the UP position.

WARNING

When the power take-off is not in use, the clutch control lever (1) fig.12 should be in the disengaged position (UP). 13

DANGER Always check that the plastic guards on the drive shaft are in perfect condition.

IMPORTANT: To prolong release bearing life RAISE the PTO clutch control lever (1), fig. 12, when the PTO will not be used for long periods of time.

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

TROUBLESHOOTING FOR MECHANICAL PTO Faults

Possible causes

Solutions

Slipping with loss of speed of PTO Wear of clutch disc or of engine output shaft. flywheel pressure plate. Poor adjustment of PTO clutch control lever.

Check the data given in the appropriate pages of section 18, replace the worn parts and adjust the clutch control lever.

Difficulty in selecting PTO speed External control stiff. by means of lever (2) fig. 11.

Check the control lever.

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

OVERHAUL 540 MECHANICAL PTO Removal

WARNING

Lift and handle all heavy parts using lifting tackle of sufficient capacity. Make sure that the units or parts are supported by suitable harnesses and hooks. Check that no one is in the vicinity of the load to be lifted. 1. Disconnect the negative cable from the battery. 2. Remove the top link (1) of the three-point linkage.

TRE0819A

14 3. Remove the tow hook (1), if fitted.

24953

15 4. Remove the tow bar (1), if fitted.

24954

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

5. Remove the six tow hook support bolts (1). There are three on the left side and three on the right side.

24955

6. Drain out the transmission/gearbox oil by removing drain plug (1).

IMPORTANT: Collect oil in a suitable container.

24956

18 7. Remove the PTO speed selector control lever (1).

19 8. Remove the screws (2) that fasten the retaining bracket (1) for the PTO speed selector control.

1 2

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 9. Remove the two upper screws (1) which fasten the PTO unit to the transmission.

24957

21 10. Insert the two guide pins 380001597 (1) and remove the two lower screws (2) which fasten the PTO unit to the transmission.

24958

2 22

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

11. Engage the lever (1) fig. 9, in position (C), ground speed PTO, so that the sleeve (3) fig. 10, rests on the shaft (2) during the removal operation. Withdraw the PTO unit by a few centimeters and detach using the hook with lifting chain 380000227 (1).

Installation 1. Clean the mating surfaces between the transmission and PTO cover and apply sealing compound as shown in figure 24. 2. Raise the PTO unit and position it directly behind the transmission casing. Slide the PTO cover onto the guide pins 3800001597, for ease of assembly. 3. Remove the hook with chain (1) fig. 23, and fasten the PTO unit using the four screws. 4. Remove the two guide pins 3800001597. 5. Install the bracket (1) fig. 8, that retains the PTO speed selector control lever. 6. Install the tow bar support. 7. Install the tow bar, the tow hook and the threepoint linkage top link. 8. Screw in and tighten the oil drain plug and fill the transmission/gearbox with oil. 9. Reconnect the negative battery cable.

24961

26282

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

540 RPM PTO Disassembly

WARNING Handle all parts with great care. Do not place hands or fingers between one part and another. Always wear the prescribed safety clothing, including protective glasses, gloves and shoes.

1. Place the PTO unit in the vice on the work bench (1).

24962

2. Use a punch to straighten the corrugations (1) on the ring nut that retains the driven shaft components.

24963

26 3. Remove the ring nut (1) from the driven shaft.

24964

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

4. Remove the four PTO unit internal support fixing screws (1).

24965

28 5. Remove the pin (1) securing the fork rod.

29 6. Withdraw the rod (1) from the rear cover.

24967

30 7. Partially withdraw the PTO output shaft (1) and remove the internal support (3) together with the driving shaft (2), the driven gears (4), the sleeve and the engagement/disengagement/neutral control fork of the 540 PTO. Also, retain the thrust washer from the gear (24) fig 2 or 3, for reuse during reassembly.

4 3 24968

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 8. Remove the rear bearing thrust washer (1) and remove the secondary shaft (2) complete with PTO output shaft.

21 2

24969

32 9. Remove the retaining snap ring, the bearing (1) and the seal (if it needs replacing) from the rear cover.

24970

33 Assembly Refer to fig. 3 and proceed as follows: 1. Mount the seal (9) (if removed in step 20), the rear bearing and the retaining snap ring (5) on the rear cover. 2. Install the thrust washer on the driven shaft. 3. Install the driven shaft gear (23), the fixed gear (21), the sleeve (22), the fork and the fork support rod. 4. Insert the gear (24) onto the driven shaft, mount the internal support (13) complete with driving shaft (25). Fasten the support (13) using the four screws, tightening them to the torque setting specified on page 5. 5. Mount the thrust washer on gear (24) and install the bearing on the internal support (13) of the driven shaft. 6. Fasten the rod that supports the PTO speed selector control fork pin as removed in step 5. 7. Tighten the driven shaft locking ring nut to the torque specified on page 5, then, using a suitable punch, corrugate the edge in order to prevent it from loosening.

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

22 540/1000 RPM PTO Disassembly

WARNING Handle all parts with great care. Do not place hands or fingers between one part and another. Always wear the prescribed safety clothing, including protective glasses, gloves and shoes. 1. Place the PTO unit in the vice on the work bench (1).

24962

34 2. Remove the bolts (1) and take off the cover (2).

2 TRE1000A

35 3. Remove the spacer (1).

1 TRE1001A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 4. Remove the two socket head screws (1) and take off the PTO engagement mechanism (2) completely.

2 1

TRE1002A

37 5. Withdraw two rods (1) from the cover. C4: Shaft securing nut tightening torque: 255 N⋅m (188.0783 ft-lb). C6: Cover retaining bolts tightening torque: 98 N⋅m (72.2811 ft-lb).

1 C4 C6

TRE1003A

38 6. Remove the nut (1) securing the shaft and take off the 4 bolts (2).

1 2 TRE1004A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

7. Remove the socket head screw bolt (1) on the side of the cover.

TRE1005A

40 8. Remove the cover (1).

TRE1006A

41 9. Remove the washer (1) and take off the gear (2).

TRE1007A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1 10. Remove the rod (1), spring (2), fork (3) and the synchronizer (4).

25 3

1 2

TRE1008A

43 11. Remove the driven gear (1).

TRE1009A

44 12. Remove the circlip (1).

TRE1010A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

13. Remove the drive shaft (1).

TRE1011A

46 14. Remove both bearings (1) and (2).

TRE1012A

47 15. Remove the shaft (1) and the plate (2).

TRE1013A

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

Assembly To reinstall, reverse the removal procedure and refer to fig. 5 and proceed as follows: — Mount the shaft (1) and the plate (2) on the rear cover (fig. 48). — Refit the two bearings (1 and 2) (fig. 47). — Refit the drive shaft (1) (fig. 46). — Install the circlip (1, fig. 45) securing the bearing. — Insert the gear (1, fig. 44). — Install the rod (1), spring (2), fork (3) and the synchronizer (4, fig. 43). — Install the washer (1) and the gear (2, fig. 42). — Install the cover (1, fig. 41). — Install the socket head screw (1, fig. 40) on the side of the cover. — Install the nut (1) securing the shaft and refit the 4 bolts (2, fig. 39). Tighten the nut (1) to 255 N⋅m (188.0783 ft-lb) and bolts (2) to 98 N⋅m (72.2811 ft-lb). — Install the two rods (1) fig. 38. — Refit the PTO engagement mechanism (1, fig. 37) and install the socket head screws securing the mechanism. — Install 1000 rpm PTO shaft with related circlip.

NOTE: The adjustment procedure should be done ONLY with the PTO shaft installed. — Using a screwdriver (1) and a spanner (2) adjust the distance X to “0 mm (0 in)” fig. 49. — Install the spacer (1, fig. 36). — Install the cover (2, fig. 35) and tighten the bolts (1). — Use suitable hooks to assemble the unit to the tractor fig. 34.

TRE1014A

X 49

SECTION 31 -- POWER TAKE-OFF -- CHAPTER 1

SECTION 33 -- BRAKES -- CHAPTER 1

SECTION 33 - BRAKES Chapter 1 - Brakes CONTENTS Section

Description

Page

SECTION 33 -- BRAKES -- CHAPTER 1

SPECIFICATIONS Type: -

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath discs acting on differential half-shafts

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

with oil bath discs acting on differential half-shafts with oil bath discs acting on the bevel pinion shaft by means of a gear ( Optional )

Control: -

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

hydraulic assisted, mechanical, with independent pedals (connectable by means of a pin)

parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mechanical, by means of a hand lever

Disc material for service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

organic agglomerate

Disc material for parking brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

steel

Mobile sector material for parking brake . . . . . . . . . . . . . . . . . . . . .

sinter or organic agglomerate

Disc thickness: -

service brake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

Discs per service brake:

4 (0.157) 4

Thickness of mobile sectors for parking brake: -

lateral sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

3.1 - 3.4 (0.122 - 0.134)

intermediate sectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

4.2 - 4.5 (0.165 - 0.177)

Adjusting the control pedals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

see page 15 (continued)

SECTION 33 -- BRAKES -- CHAPTER 1

TORQUE SETTINGS PARTS TO BE TIGHTENED

Thread

Nuts securing final drive box to transmission box (C1) . . . . . . . . .

M 12 x 1.25

TRE0300A

Tightening torque N⋅m

ft-lb

72.281

C1 - 98 N⋅m 1

SECTION 33 -- BRAKES -- CHAPTER 1

SECTIONAL VIEW 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 20.

Sectional drawing of service brakes1. Brake link Pin Ball Brake actuator Brake discs Back-up discs Actuator return spring Differential support Axle shaft Boot cover plate Boot Differential support retaining bolt

TRE0301A

NOTE: When mounting apply sealing compound to surfaces X as shown on page 3.

SECTION 33 -- BRAKES -- CHAPTER 1

BRAKES

T 8

6 5 9

Lm 1 Pd

a c

PARK BRAKE & SLAVE CYLINDER 1 14 13

View of service and park brake controls a. b. c. Lm. M. Pd. SL.

R.H. brake pedal in rest position and L.H. brake applied. Brakes applied. Brakes in rest position. Parking brake hand lever. Brake pedal return springs. R.H. brake pedal. Slave cylinder

MS. Master cylinder T. Parking brake link. 1. Brake links. 3. Actuator ball. 4. Brake actuator. 5. Brakes discs. 6. Back--up discs.

7. 8. 9. 12. 13. 14. 15.

Actuator return spring. Differential support. Axle shaft. Final drive housing. Park brake control lever. Park brake control cable. Brake pivoting shaft.

SECTION 33 -- BRAKES -- CHAPTER 1

DESCRIPTION AND OPERATION SERVICE BRAKES The service brakes are hydraulic with oil bath discs. The two control pumps (one for each pedal) are housed in the front section of the cab and are connected to their respective pedals by means of two rods. These pumps can be actuated either independently or together. If actuated together, the pedals are connected by a pin. A connecting pipe between the two pumps ensures balanced braking even when the brake discs are not equally worn. The two control pumps are fed from a single tank located above the pumps. Refer to the illustrations on page 5. The service brakes are slave cylinder operated. When the left--hand brake pedal (fig. a ) is depressed, the master cylinder (MS) sends the oil to the slave cylinder (SL). The brake links (1) move as indicated

by the arrows, by the help of slave cylinder (SL) this causing actuator discs to turn, ball (3) in the tapered seats to force the discs apart as shown in detail (c). As a result, two simultaneous actions compress the brake discs against the differential support (8) and the back up discs, immediately upon releasing the pedal spring (7), pull the actuator (4) back into the rest position (figure b and detail d) and as a result the discs are released. The action is similar when the right--hand brake pedal is pressed (Rd). The brake discs (one for each rear wheel) are positioned between the rear transmission box and the lateral final drive box and are splined onto the differential output half--shafts. PARKING BRAKE Refer to the illustrations on page 5. When the hand brake lever (Lm) is pulled, the control cable (14) pulls the control lever (13), at the direction of arrow. Then the brake links (1) acts on the brake discs.

SPECIAL TOOLS

WARNING Engage the parking brake on the windrower, shut the engine down, and wait for all moving parts to stop before leaving the cab. Failure to comply could result in death or serious injury. The operations described in this section must be performed only with the ESSENTIAL equipment marked with (X). To operate safely and achieve best results however, while saving time and effort, essential equipment must be used in conjunction with the special tools recommended below, and tools which you must make yourself and for which you will find the design in this manual.

List of special tools necessary for the various operations described in this section. X 380000822 Driver for boot installation. 380000227 Lifting hook.

SECTION 33 -- BRAKES -- CHAPTER 1

TROUBLESHOOTING Problems Braking ineffectual.

Unbalanced braking.

Possible causes

Solutions

Friction material on brake discs Replace the brake discs. worn.

Incorrect tire pressure.

Inflate the tires to the correct pressure.

Friction material on one of the Replace the discs. brake discs worn. Braking noisy.

Parking brake does not lock.

Friction material on brake discs Replace the discs. worn. Braking sectors worn.

Replace the braking sectors.

The tractor continues to be braked Braking sectors seized on brake Release and replace damaged parts. when the parking brake is disen- discs. gaged.

SECTION 33 -- BRAKES -- CHAPTER 1

OVERHAUL RIGHT HAND OR LEFT HAND BRAKE (SERVICE BRAKES) Removal

DANGER Lift and handle all heavy parts using lifting equipment of adequate capacity. Make sure that the units or parts are supported by appropriate harnesses and hooks. Make sure that there is no one in the vicinity of the load to be lifted. Proceed as follows to remove the lateral final drive box. 1. Disconnect the negative battery cable (1).

2. Lock the front wheels using chocks.

25621

3. Remove the vertical rod (1) and the LH stabilizer strut (2).

2 1 26253

4. Raise the rear section of the tractor and place a fixed stand, 1, underneath the bending bar support.

25647

1 5

SECTION 33 -- BRAKES -- CHAPTER 1

5. Remove lug nuts and remove the rear LH wheel.

25646

6. Remove the bolts (1) securing the cab to its mounting 7. Raise the cab slightly and place a suitable piece of wood between the hydraulic lift and the cab, taking care to avoid contact with pipes.

TRE0193A

8. Remove the plug (1) and drain the oil from the rear transmission--gearbox casing.

25622

9. Remove the bolts securing the cab to its mounting (1).

TRE0193B

SECTION 33 -- BRAKES -- CHAPTER 1 10. Position a jack stand (1) underneath the rear section of the fuel tank.

25505

11. Fit lifting hooks (1) 380000227 onto the lateral final drive box. Connect a hydraulic lift to the hooks, remove the retaining bolts and remove the LH lateral final drive box from the transmission box. 1

TRE0188A

12. Remove the pin.

TRE0214A

13. Back off link (1) from spring side and remove the complete brake unit. 14. Check actuator and brake discs for wear.

12 1

TRE0215A

SECTION 33 -- BRAKES -- CHAPTER 1

Installation

WARNING

Use appropriate tools to align the holes. NEVER USE YOUR FINGERS OR HANDS. — Refer to the illustrations on page 5 for the correct orientation of the various components. — Before refitting the lateral final drive box to the rear transmission box, thoroughly clean and degrease the mating surfaces and apply a strip of sealing compound of diameter about 2 mm as shown in the illustration on page 13. — Apply the torque settings listed on page 3. 1. Using tool 380800022 as shown to position boot (11) correctly on brake link (1). (See fig. 14) 2. Install the brake disc and spacers. 3. Using tools 380000227 and a hydraulic lift, install the lateral final drive complete with axle shaft and rear reflector. 4. Install the rear cab mounting retaining bolts. 5. Remove the piece of wood between the cab and the lift body. 6. Tighten the bolt securing the cab to the rear LH support. 7. Install the LH wheel. 8. Install the stabilizer strut and the vertical rod. 9. Remove the stands. 10. Install oil drain plug and fill. 11. Connect the negative battery cable.

TRE0303A

SECTION 33 -- BRAKES -- CHAPTER 1

TRE0304A

15 Diagram for application of sealing compound when fitting braking assembly and lateral final drives on transmission box. The types of sealing compound to be used are specified in sect. 00.

SECTION 33 -- BRAKES -- CHAPTER 1

HYDRAULIC BRAKE SLAVE CYLINDER

Removal--Refitting (Op. 33 202 50)

Proceed as follows to remove the hydraulic brake slave cylinder. 1. Remove the pin (1).

2. Remove the bolts securing the pump (2). 3. Take off the pipe connections (3) and (4). TRE0214A

16 4. Withdraw the slave cylinder (1) from link.

1 TRE0213A

17 5. Remove the front hydraulic pump internal parts. Check the seals and piston.

WARNING Use appropriate tools to align the holes. NEVER USE YOUR FINGERS OR HANDS. TRE0306A

18 Installation Install the hydraulic brake slave cylinders as follows. 1. Insert the master cylinder (1) from link. (Figure 17) 2. Install the pin (1). (Figure 16) 3. Assemble the bolts securing the pump (2). (Figure 16) 4. Assemble the pipe connections (3) and (4). (Figure 16)

SECTION 33 -- BRAKES -- CHAPTER 1

SERVICE BRAKE PEDALS Adjusting Height of Service Brake Pedals (Op. 33 120 08 ) 1. With the brake pedals connected to their respective forks and the pedal connecting pin removed, check that the height (A) from the centre of the pedals to the top of the carpet is: 162 mm for tractors fitted with cab or 205 mm for tractors without cab.

19 2. If adjustment is required, slacken the lock nuts (2) and tighten or slacken bolt (1) until the required height (A) is obtained. Lastly tighten the lock nuts.

20 3. The length of the brake links must be 190mm Âą1mm. If adjustment is required, fully release the handbrake (lever down). Remove the connecting pin (3). Slacken the lock nuts (1) and turn the hexagon sleeves (2) until the length of brake links is 190 mm. Finally, tighten the lock nuts (1).

1 2 3

L TRE0229A

SECTION 33 -- BRAKES -- CHAPTER 1

SECTIONAL VIEW OF SLAVE CYLINDER

SECTION 33 -- BRAKES -- CHAPTER 1

HAND BRAKE CONTROL Adjusting Travel (Op. 33 110 08) The travel of the parking brake control lever must be adjusted whenever work is carried out on the unit and when the lever is not on the third notch of the gear sector when the brake is engaged. Proceed as follows.

1. Slacken the lock nut (1). 2

2. Tighten or slacken the adjusting screw (2) until the control lever is locked on the third notch. 3. Tighten the lock nut (1).

TRE0217A

SECTION 33 -- BRAKES -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS Chapter 1 -- Hydraulic Systems

CONTENTS Section

Description

Page

Precautionary Statements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic System -- Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Auxiliary (Rear) Control Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Double-Acting Cylinder Lift Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Double-Acting Cylinder Lower Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Single-Acting Cylinder Lift Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Single-Acting Cylinder Lower Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Double-Acting Cylinder with Automatic Detent Release Lift Phase . . . . . . . . . . . . . 8 Double-Acting Cylinder with Automatic Detent Release Lower Phase . . . . . . . . . . 9 Rear Remote Valve Control Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Control Lever Positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Quick-Release Couplers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Switching Between Single and Double Acting Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . 11 Mechanically Controlled Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Fast Raise/Lower Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Principles of Draft Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Principles of Position Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Principles of Float . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Principles of Draft and Position Control Combined . . . . . . . . . . . . . . . . . . . . . . . . . 13 Hydraulic Lift Oil Flow (Lift Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydraulic Lift Oil Flow (Neutral Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic Lift Oil Flow (Lowering Phase) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Three-Point Hitch (Category I and II) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Adjustable Length Top Link . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Right-Hand Lift Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Telescopic Lateral Stabilizer Struts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Lower Links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Left-Hand Lift Rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 PRECAUTIONARY STATEMENTS

WARNING

Never use your hands to locate a leak. Hydraulic leaks under pressure may penetrate the skin and possibly cause severe injury, or death. A piece of cardboard or a rag usually will sufficiently identify a leak without risking personal injury.

Stand clear of all moving parts when starting the engine or pressurizing the hydraulic system.

WARNING Always turn-off the engine and bleed any remaining hydraulic pressure before connecting or disconnecting hydraulically operated equipment, components or connectors. Hydraulic oil under pressure may cause severe injury or death.

WARNING Ensure all hydraulic connections remain tight before starting the engine or pressurizing the hydraulic system. Hydraulic oil under pressure may cause severe injury or death.

WARNING Always stand clear of equipment raised with a hydraulic system, as a failure, leak or sudden loss of pressure will cause the equipment to drop. Severe injury or death may occur from unexpected falling equipment.

CAUTION Contamination of the hydraulic oil will lead to premature failure of components, or catastrophic failure of the entire system. Use protective closures, and keep work areas clean before, during and after maintenance on the hydraulic system.

CAUTION Operating the hydraulic system above recommended operating temperature for long periods will destroy O-rings and seals, as well as break down the lubricating properties of hydraulic oil. This will result in internal corrosion or leakage, which will lead to component and/or system failure.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC SYSTEM -- DESCRIPTION AND OPERATION The TD series tractor is equipped with a dual pump, low-pressure and high-pressure, open-center hydraulic system. Both systems share a main hydraulic filter, and the rear axle housing as a reservoir. For information on the Steering System, refer to Section 41. The high-pressure system supplies oil for the operation of the hydraulic lift, remote control valves, and external equipment. In addition, the high-pressure system in combination with the 3-point hitch provides accurate and sensitive control of implements over a wide range of operating conditions. The high-pressure system is an open-center type, which allows for the continuous flow of oil through the system and back to return. This type of system reduces wear on the control valve seals, and prevents damage to components caused by prolonged static pressure. A relief valve, 1, installed in the auxiliary control valve block, protects the high-pressure (lift) system from excessive pressure.

TRE0139A

1 A filter assembly, 1, located on the right-hand side of the engine, cleans the oil before it enters the highpressure system. In the high-pressure system, the rear remote valves have oil priority over the hydraulic power lift (HPL). When operating a remote valve(s), oil flows from the remote valve to the actuated cylinder. Return oil from the cylinder flows back through the remote valve assembly to sump. The hydraulic lift is not operable during operation of a remote control valve.

TRE0841A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

The oil level in the rear axle/transmission housing is replenished and checked at the dip stick, 1.

TRE0015A

3 When necessary to drain the hydraulic oil, remove the plug, 1, located under the rear axle housing on the left-hand side.

TRE0050A

1 4

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC SYSTEM DIAGRAMS HYDRAULIC DIAGRAM ON TD80D AND TD95D BASE MODELS

11 13 7

6 5

8 9 1

14 2

50037333

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

Rear Axle Casing (high-pressure system reservoir) Filter Assembly (high-pressure) High-Pressure (Lift) Pump 13.6 g/m (51.7 L/m) Pressure Relief Valve (rated 186 -- 191 bar [2697 -- 2770 psi]) Rear Remote Control Valve with Automatic Detent Release (4th remote valve -- optional) Quick-Release Connectors Lift Control Valve

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

Lift Cylinder Lift Arms Steering Pump 8.1 g/m (30.8 L/m) Pressure Relief Valve (2WD -- 100 bar [1450 psi]) (FWD -- 125 bar [1813 psi]) Hydrostatic Steering Control Valve Steering Cylinder Steering Filter Assembly (internal to reservoir) Self-Contained Steering System Reservoir

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

HYDRAULIC DIAGRAM ON TD95D HIGH CLEARANCE MODELS

6 12

14 13

8 9

15 1

50037332

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

Rear Axle Casing (high-pressure system reservoir) Filter Assembly (high-pressure) High-Pressure (Lift) Pump 13.6 g/m (51.7 L/m) Pressure Relief Valve Rear Remote Control Valve with Automatic Detent Release Rear Remote Control Valve with Automatic Detent Release and Float Function (4th remote valve -- optional) Quick-Release Couplers

8. 9. 10. 11. 12. 13. 14. 15. 16.

Lift Control Valve Lift Cylinder Lift Arms Steering Pump 8.1 g/m (30.8 L/m) Pressure Relief Valve (2WD -- 100 bar [1450 psi]) (FWD -- 125 bar [1813 psi]) Hydrostatic Steering Control Valve Steering Cylinder Steering Filter Assembly (internal to reservoir) Self-Contained Steering System Reservoir

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 AUXILIARY CONTROL VALVES Double-Acting Cylinder Lift Phase (Refer to Figure 7) On pulling back the control lever, (located in the cab) the control valve spool, 2, moves to connect: pressure line (P) with the lower chamber of the cylinder by way of line (A), and also exhaust line (T) by way of line (B), 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 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 line (P).

7 A

TRE0712A

2 7

Pressurized oil Suction, delivery or exhaust oil Static oil

Double-Acting Cylinder Lower Phase (Refer to Figure 8) To lower the implement, push the control lever (located in the cab) forward. The control valve spool, 2, will move to the position indicated in fig. 8, thus allowing the oil in the lower cylinder chamber to flow to the exhaust (T) through line (A), while the upper chamber is connected to the pressure line (P) through line (B) .

TRE0713A

T 2 8

Single-Acting Cylinder Lift Phase (Refer to Figure 9) On pulling the control lever back, the control valve spool, 2, fig. 9 moves to connect the cylinder with the pressure line (P) by way of line (A). Line (C), for the control of single--acting cylinders, is used in this stage as it is permanently connected to the exhaust (T) by the open position of the switching valve, 1.

TRE0714A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Single-Acting Cylinder Lower Phase (Refer to Figure 10) On pushing the control lever forward, the spool, 2, will move to the position indicated in fig. 10. The oil contained in the cylinder, pressurized by the weight of the lifted implement, will flow to the exhaust (T) by way of line (A), while the entire flow from the pump is also conveyed to the exhaust (T) through the line (B).

NOTE: To operate a double--acting cylinder, tighten screw, 1, fully home. To operate a single--acting cylinder, fully undo screw, 1.

TRE0715A

2 10

Double--Acting Cylinder with Automatic Detent Release Lift Phase Pressurized oil Suction, delivery or exhaust oil

Static oil

TRE0716A

V 11

On pulling back the control lever, the spool, 2, moves and the detent balls, 26, engage the groove, where they are held in place by the support, 28, and spring, 24. The movement of the spool (2) connects: the pressure line (P) with the line (B), and also the upper cylinder chamber with the exhaust line (T) by way of line (A), intercepting the supply of oil to the hydraulic lift control valve.

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, releasing the spool, 2, which, under the action of spring, 6, returns to neutral position. Consequently the entire flow from the pump is conveyed to the lift control valve through lines (P).

On completion of the lifting movement, the oil pressure increases to 120--130 bar (1740 -- 1885 psi). Acting through port (V), it overcomes the resistance of the spring of the needle valve, 23. Inside chamber (D), the

NOTE: Auxiliary Control Valves with the automatic detent release (kick-out) feature, are factory adjusted to a pressure of 120--130 bar (1740--1885 psi).

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Double--Acting Cylinder with Automatic Detent Release Lower Phase 28 6

TRE0717A

T 12

To lower the implement, push the control lever forward. The control valve spool, 2, moves and the detent balls 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 (T) by way of line (B), while the upper chamber is connected with the pressure line (P) by way of line (A). On completion of the lowering operation, the detent will be automatically released in the manner described previously. Rear Remote Valve Control Levers Each rear remote valve contains a corresponding lever, 1, on the right-hand side of the operatorâ&#x20AC;&#x2122;s seat, for operational control via mechanical linkage. For quick identification, color markings match each lever with the respective control valve, flow control knob, and coupling. Depending on the type of remote valve, the control lever functions within three or four positions as follows:

TRE0804A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Lifting – Pulling the lever rearward (A) extends the corresponding cylinder to lift or raise the implement.

Neutral – Pushing the lever forward (B) returns the valve to the neutral position and the deactivated cylinder stops moving the implement. Rear remote valves, incorporating the detent-releasing feature, will automatically return the valve to the neutral position when the cylinder reaches the end of the stroke. Lowering – Pushing the lever forward past the neutral position (C) retracts the cylinder and the implement lowers. Float – Pushing the lever full forward past the lowering position (D) selects the float function. This position allows the cylinder to extend and retract freely, which permits the implement to follow the contour of the ground. The control lever will not automatically return to neutral from the float position.

TRE0804A

CONTROL LEVER POSITIONS Control Lever Position

Operation Performed

Description

Lifting

Full Rearward

Lifts the Implement

Lowering

Forward

Lowers the Implement

Neutral

In-between Rearward and Forward

Stops Lifting or Lowering

Float (where installed)

Full Forward Beyond Lowering

Implement Follows Terrain Under Own Weight

Quick-Release Couplers

WARNING

The couplers do not provide breakaway capability when connected to hoses.

NOTE: Before connecting or disconnecting quick-fit couplers, stop the tractor, and lower any attached implement. Each remote control valve contains two 1/2 inch quick release type couplers, that connect with pressurized male couplers. Connecting the control cylinder lines will thus require two hands. The couplers contain plastic caps (A) for the prevention of contamination when not in use. The valves and couplers are color coded for easy identification as follows: Valve 1

Color Green

2 3

Blue Brown

IMPORTANT: Clean the area around the coupler before connecting or disconnecting to reduce the ingestion of contaminants such as dirt into the hydraulic system.

TRE0854A

A 15

A. B. C. 1. 2. 3.

Plastic Caps Cylinder Retract Couplers Cylinder Extend Couplers Auxiliary Remote Valve One Auxiliary Remote Valve Two Auxiliary Remote Valve Three

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SWITCHING BETWEEN SINGLE AND DOUBLE ACTING CYLINDERS Loosen the adjusting screw, 1, completely to configure a single-acting cylinder, or tighten the screw completely to change the cylinder to from single to double acting.

1 TRE0824A

MECHANICALLY CONTROLLED HYDRAULIC LIFT The Hydraulic Power Lift system contains four distinct methods of controlling the 3-point linkage system, which includes: • Draft Control (figure 17, item 2; inside lever) • Position Control (figure 17, item 1; outside lever) • Float • Draft and Position Control Combined All TD models contain fixed link-ends with a factory upgrade option to flexible link-ends. Selection of a control system depends on the type of implement in use and the operating conditions that exist. Selection is accomplished through a position control lever, 1, and a draft selector lever, 2, in a quadrant on the right-hand side of the operator’s seat. The lower lift arms and corresponding control rods connected to the flex bar provide for draft control.

TRE0116A

17 Fast Raise/Lower Control Device The Fast Raise/Lower control device allows control of the Hydraulic Power Lift without using levers. Moving button, 2, rearward raises the arms and releases button, 1. Pressing button, 1, lowers the implement to the pre-set limit of the control lever, and remains depressed until released by button, 2.

NOTE: Lowering button, 1, must be depressed to lower the arms using the Position Control Lever.

TRE0017A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

Principles of Draft Control The Draft Control system manages the working depth of soil engaging implements to maintain an even pull on the tractor, and to reduce wheel slippage. When lowering a soil-engaging implement, e.g. a plow, into the ground, the draft forces applied to the implement tend to make the plow pivot at the point where it attaches to the lower links. The HPL senses the force on the lower link arms via a torsion bar. Without the top link, the plow would tip up. Due to the top link resistance, the plow stays level in the ground. This demonstrates compressive force acting on the top link against the tractor. The draft force will alter according to the depth of work and soil type. Move the position control lever full forward and set the implement depth in the ground by gradually shifting the draft control lever. Forward movement of the draft control lever increases implement depth and rearward movement of the lever reduces the depth. The depth reached by the implement is proportional to the traction power determined by the soil consistency. The lift automatically maintains drive power required of the tractor at a constant level. Principles of Position Control Position control allows for pre-setting and maintaining the working depth or height of an implement, relative to the tractor. Move the draft control lever full forward and set the position of the implement by shifting the position control lever forward to lower the implement, and rearwards to raise the implement. Movement of the implement is proportional to movement of the lever. In addition to the position control lever, movement of the implement is possible by using the Fast Raise/ Lower control buttons to raise and lower the implement.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 Principles of Float The float position enables the lower link arms to move freely. Shift both the draft control lever, 1, and position control lever, 2, full forward, and only use the Fast Raise/Lower control device to raise or lower the implement.

13 1

TRE0116A

19 Principles of Draft and Position Control Combined In this configuration the lift operates in draft control, and at the same time prevents the implement from protruding deep into soil of less resistance, thereby preventing soil unsuitable for crop growing from reaching the surface Set the desired draft control of the implement and gradually shift the position control lever until the lower link arms rise. Only use the Fast Raise/Lower control device to raise or lower the implement in this configuration.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

15 9

12 10

8 4

A 17

Pressurized oil Oil in suction, delivery or return Static oil TRE0702A

20 Hydraulic Lift Raise Phase A. 1. 2. 3. 4. 5. 6. 7. 8.

Internal Mechanical Linkage Rear Axle Housing (Reservoir) Filter Assembly High-Pressure System Pump Relief Valve Plunger Plunger Spring Piston Seat Piston

Hydraulic Lift Oil Flow (Lift Phase) Refer to Figure 20 Moving the control lever to the lift position transmits motion via internal mechanical linkage (Detail A) to the control valve block pin, 10. The control valve block pin interrupts oil flow to the control valve, 12, and the intervention speed-control valve, 11.

9. 10. 11. 12. 13. 14. 15. 16. 17.

Check Valve Control Valve Block Pin Intervention Speed Control Valve Control Valve Lift Cylinder Piston Lift Arms Cylinder Safety Valve Arm Descent Speed Control Valve Draft Transmission Rod

The ball unseats within the check valve, 9, installed in the lift cylinder port, allowing pressurized oil to pass through and out on the surface of the piston, 13. The force of the piston raises the left arms, 14. During controlled draft operation, the lift command transmits to the flex bar. This movement then transmits to the control valve block pin, 10, by way of the draft-transmission rod, 17.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 16

12 8

A 17 1

Pressurized oil Oil in suction, delivery or return Static oil

TRE0703A

21 Hydraulic Lift Neutral Phase A. 1. 2. 3. 4. 5. 6. 7. 8.

Internal Mechanical Linkage Rear Axle Housing (Reservoir) Filter Assembly High-Pressure System Pump Relief Valve Plunger Plunger Spring Piston Seat Piston

Hydraulic Lift Oil Flow (Neutral Phase) Refer to Figure 21 When the lift arms, 14, reach a predetermined height, the internal linkage (Detail A) becomes stationary which creates a neutral condition. The position of the control valve block pin, 10, directs oil to the control valve, 12. Oil pressure forces the piston against the spring, overcomes spring resistance, and opens a path for the oil to return to the rear axle housing, 1, instead of the lift cylinder.

9. 10. 11. 12. 13. 14. 15. 16. 17.

Check Valve Control Valve Block Pin Intervention Speed Control Valve Control Valve Lift Cylinder Piston Lift Arms Cylinder Safety Valve Arm Descent Speed Control Valve Draft Transmission Rod

In the neutral position, supply oil constantly flows through the control valve and on to the transmission casing, while at the same time pressure remains static at the lift cylinder piston to keep the lift arms in the selected position.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

14 16

15 9

12 8

A 17

Pressurized oil TRE0704A

Oil in suction, delivery or return Static oil

22 Hydraulic Lift Lower Phase A. 1. 2. 3. 4. 5. 6. 7. 8.

Internal Mechanical Linkage Rear Axle Housing (Reservoir) Filter Assembly High-Pressure System Pump Relief Valve Plunger Plunger Spring Piston Seat Piston

Hydraulic Lift Oil Flow (Lowering Phase) Refer to Figure 22 Moving the control lever to the lower position transmits motion via internal linkage (Detail A) to the control valve block pin, 10. The position of the control valve block pin opens a discharge path for oil returning from the lift cylinder piston, 13, by way of the arm descent speed control valve, 16. The loss of pressure acting on the lift cylinder piston, aided by the weight of the lift arms, 14, allows the lift arms to lower. The arm descent speed control valve, 16, which is

9. 10. 11. 12. 13. 14. 15. 16. 17.

Check Valve Control Valve Block Pin Intervention Speed Control Valve Control Valve Lift Cylinder Piston Lift Arms Cylinder Safety Valve Arm Descent Speed Control Valve Draft Transmission Rod

adjustable, determines how fast the implement lowers by reducing or expanding the return path for discharging oil. The control valve block pin provides a passage for supply oil to flow to the control valve, where it returns to the transmission casing rather than the lift cylinder. During controlled draft operation, the lowering command transmits to the flex bar, and on to the control valve block pin, 10, by way of the draft-transmission rod.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1 THREE-POINT HITCH (CATEGORY I AND II)

The main components of the three-point hitch are as follows:

1 8

Models with Cab:

1. Adjustable Length Top Link 2. Tie Rod 3. Right-hand Lift Rod 4. Telescopic Lateral Stabilizer Struts 5. Lower Links 6. Left-hand Lift Rod

6 4

4 5

TRE0818A

7. External Lift Lever

ADJUSTABLE LENGTH TOP LINK The adjustable top link, 1, connects to the support bracket, 4, and is secured with a pin. Two different sets of holes in the support bracket provide for a higher, or lower positioning of the top link, depending on the implement. With the top link secured in the upper hole, maximum lift capacity with the largest implement to cab clearance is achieved. With the top link secured in the lower hole of the support bracket, maximum ground penetration is available. When not in use, a catch, 3, holds the top link in the up position. A bar, 2, adjusts the length of the top link, which must not exceed 870 mm (34.25 in).

3 2 1

TRE0819A

RIGHT-HAND LIFT ROD Adjust the length of the right-hand lift rod by lifting the sleeve, 1, to release it from the drift pin, 2, and rotate the sleeve to achieve the desired length. Ensure the sleeve lowers completely over the drift pin to prevent inadvertent rotation of the sleeve.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

TELESCOPIC LATERAL STABILIZER STRUTS To adjust the stabilizer struts, 1, remove the pin, 2, which will allow the lower links, 3, to swing freely. Widen or shorten the clearance between the left and right lower links and reinstall the pin, 2, into the appropriate hole corresponding with the clearance required. The lateral movement of the lower links must not exceed 120 mm (4.72 in) each side.

1 2 3

TRE0801A

LOWER LINKS When operating the tractor in draft, or combined draft and position control, install the spacers, 1, of the lower links, 2, on the inner side of the links. This installation provides greater sensitivity when working with light equipment or light draft loads.

24252

27 For normal or heavy work, install the spacers, 1, of the lower links, 2, on the outward side of the links. This installation reduces lift sensitivity when working with heavy equipment or heavy draft loads.

24253

1 28

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

LEFT-HAND LIFT ROD Adjust the length of the left-hand lift rod, 1, by turning the link end, 2, in or out, to set implement working position parallel to the ground.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 1

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SECTION 35 - HYDRAULIC SYSTEMS Chapter 2 - Hydraulic System Overhaul

CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional Views . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Mechanically Controlled Hydraulic Lift . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Adjusting the HPL on a Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 HPL on the Workbench . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Position Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Draft Control Linkage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Fast Raise/Lower Control Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Lift Pressure Relief Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Lift Control Valve Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 High-pressure (Lift) Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Inspection and Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

2 Section

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 Description

Page

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SPECIFICATIONS MECHANICALLY CONTROLLED HYDRAULIC HITCH Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

position or draft control with a combination of the two

Operating system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

two independent levers

Fast Raise/Lower Control Device . . . . . . . . . . . . . . . . . . . . . .

provides fast lifting/lowering operations using pushbuttons, without using the position or draft control levers

Single-acting cylinder: -

rated diameter and stroke: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in)

100x128 (3.936 x 5.039)

capacity: All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 (in3)

1005 (33)

Pressure relief valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

186 - 191 (2698 - 2770)

Cylinder safety valve setting . . . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

210 - 215 (3046 - 3118)

Lift piston diameter: -

All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in)

Internal diameter of cylinder liner: - All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (in) Clearance between piston and liner . . . . . . . . . . . . . . . . . . . . mm (in)

99.980 - 100.000 (3.936 - 3.937) 100.036 - 100.071 (3.938 - 3.939) 0.036 - 0.091 (0.001 - 0.003) (continued)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

MECHANICALLY CONTROLLED HYDRAULIC HITCH Diameter of lift arm shaft at position of bushings: - right-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

54.970 - 55.000 (2.164 - 2.165)

mm (in)

62.670 - 62.700 (2.467 - 2.468)

left-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Internal diameter of bushings installed on lift body: -

right-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

55.100 - 55.184(1) (2.169 - 2.172)

left-hand side . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

62.800 - 62.884(1) (2.472 - 2.475)

Clearance between lift arm shaft and bushings . . . . . . . . . . .

mm (in)

0.100 - 0.214 (0.003 - 0.008)

Interference between bushings and their seats . . . . . . . . . . .

mm (in)

0.065 - 0.185 (0.002 - 0.007)

Axial clearance of shaft complete with lift arms . . . . . . . . . . .

mm (in)

0.2 - 1.4 (0.007 - 0.055)

External diameter of draft control idler shaft . . . . . . . . . . . . . .

mm (in)

21.967 - 22.000 (0.864 - 0.866)

Internal diameter of seats in support . . . . . . . . . . . . . . . . . . . .

mm (in)

22.020 - 22.072 (0.866 - 0.868)

Clearance between idler shaft and seat . . . . . . . . . . . . . . . . . .

mm (in)

0.020 - 0.105 (0.0007 - 0.004)

Diameter of position control idler shaft . . . . . . . . . . . . . . . . . . .

mm (in)

13.973 - 14.000 (0.550 - 0.551)

Internal diameter of position control idler shaft . . . . . . . . . . . .

mm (in)

14.016 - 14.059 (0.552 - 0.553)

Clearance between draft control idler shaft and position control idler shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.016 - 0.086 (0.0006 - 0.003)

Clearance between control valve block pin and seat on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.008 - 0.012(2) (0.0003 - 0.0004)

Clearance between lift control valve and seat on the control valve block body . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.008 - 0.012(2) (0.0003 - 0.0004)

mm (in)

50.5 (1.988) 34 (1.338)

mm (in)

44 (1.732)

Control valve block pin return spring: -

free spring length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . spring length under load of 31.7 - 35 N (7.12 - 7.86 lb) .

Control valve return spring -

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

spring length under load of 103 - 114.7 N (23.15 - 25.78 lb))

29 (1.141)

(1)

Valve 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. (continued)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

THREE-POINT HITCH IMPLEMENT HITCHING DEVICE Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Category: - All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

three-point linkage

Draft control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of lower arms with flex bar

Maximum liftable load with center of gravity 610 mm (24 in) from the lower arm link ends: with arms horizontal (with top link connected to hole on upper support): . . . . . . . . . . . . . . . . . . . .

kg (lbs)

2700 (5952)

Maximum liftable load: with arms horizontal (with top link connected to upper support pin): . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg (lbs)

3565 (7859)

Flex bar diameter: - All models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

24.867 - 24.900 (0.979 - 0.980)

Axial clearance of flex bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

1.2 - 4.1 (0.047 - 0.161)

HYDRAULIC PUMP C31 (All models) Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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) . . . . . . . rpm Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min (gpm)

paper cartridge mounted on pump body, suction side gear type with oil suction from transmission casing flanged on the rear left-hand side of the engine A31 BOSCH driven by timing gears Counter Clockwise 1:0931 2328 34.5 (9.2)

44.5* (11.7)*

Bench output at 1450 rpm and pressure of 172 bar (2446 psi): -

for new or reconditioned pump . . . . . . . . . . . . . . . . . . . dm3/min (in3/min) for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in3/min) test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C° (F°) test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

* Optional

19 (1159.5) 13.3 (811.6) 55 - 65 (131 - 149) SAE 20 (continued)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

HYDRAULIC PUMP (All Models) Driven and driving gear shaft diameter . . . . . . . . . . . . . . . . . . . . . .

mm (in)

17.400 - 17.418 (0.685 - 0.686)

Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

17.450 - 17.470 (0.687 - 0.688)

Clearance between gear shafts and their seats . . . . . . . . . . . . . . .

mm (in)

maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.032 - 0.070 (0.001 - 0.002) 0.1 (0.004)

Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.020 - 0.064 (0.0008 - 0.002)

Maximum wear on pump body, suction side, at position of gears

mm (in)

0.1 (0.004)

Width of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

24.000 - 24.015 (0.944 - 0.984)

Width of supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

24.490 - 24.510 (0.964 - 1.004)

Width of pump body for gear seats and supports . . . . . . . . . . . . .

mm (in)

73.135 - 73.160 (2.879 - 2.880)

Axial clearance of gears complete with supports in pump body (recondition if necessary) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (in)

0.100 - 0.180 (0.004 - 0.007)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Auxiliary Control Valves Filter Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

paper cartridge

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

fixed to the pump housing on suction side

Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from transmission casing

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

Flanged on the rear left-hand side of the engine

Construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bosch-Rexroth

Actuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

by means of the engine gears

Direction of rotation (as seen from drive side) . . . . . . . . . . . . . . . .

counterclockwise

Engine speed to pump speed ratio . . . . . . . . . . . . . . . . . . . . . . . . . .

1 : 1.080

Maximum speed of pump rotation (with engine at maximum power equivalent to 2500 rpm) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm

2700

Nominal flow rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/turn (in3/turn)

0.01950 (1.930)

Corresponding rated output for new pump . . . . . . . . . dm3/min (in3/min)

48 (2929)

Corresponding rated output for pump with 300 hours of work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in3/min)

43 (2624)

Bench output at 1500 rpm and a pressure of 2175 psi (150 bar): -

for new pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . dm3/min (in3/min)

24.8 (1513)

for pump with 300 hours of work . . . . . . . . . . . . . . dm3/min (in3/min)

22.3 (1361)

test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

55 to 65 (131 to 149)

test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Â°C (Â°F)

16 CST

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 TIGHTENING TORQUES Thread

Torque setting Nâ&#x2039;&#x2026;m

ft-lbs

Lift Capscrew, lift to rear transmission case . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

Capscrew, control valve body to lift . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 8 x 1.25

Capscrew, lift arm plates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

147

108

Plug, max. arm raising adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

103

Nut, position control shaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Nuts for lever quadrant bracket securing stud bolts . . . . . . . . . . . . . .

M8x1.25

Lift cylinder securing bolts:

M14x1.5 M16x1.5

211 260

155 191

Securing bolts for top link attachment bracket . . . . . . . . . . . . . . . . . .

M14x1.5

147

108

Inner lift arm securing bolts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Capscrew, suction connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 12 x 1.25

Capscrew, delivery connection on lift control valve . . . . . . . . . . . . . .

M 10 x 1.25

Capscrew, lift pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M6x1

Nut, pump cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Capscrew, flexion bar support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163

Capscrew, chain support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163

Capscrew, check link support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

221

163

Nut, tow bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

343

252

Control valves Nut, control valve links . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Connection, outlet to fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Plug, relief bar spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SPECIAL TOOLS

WARNING The operations described in this section cannot be carried out without the ESSENTIAL tools marked below with (X). However, to ensure greater safety and obtain the best results while saving time and effort, we recommend that these essential tools are used in conjunction with the specific tools listed below as well as certain tools which are to be made following the construction drawings given in this manual. 380000262 Punch for fitting lift arm shaft seal. 380000261 Punch for fitting needle bearings on control valve block control lever bushing. 380000260 Punch for fitting needle bearings to upper/lower draft control levers and to draft control link rod. 380000230 Wrench for cylinder safety valve setting ring nut. 380000231 Wrench for lift pressure relief valve setting ring nut. 380000225 Ring for lifting piston with lift seals.

380000215 Hand pump for valve calibration. 380000218 Union for cylinder safety valve calibration. 380000217 Union for lift pressure relief valve calibration. X 380000267 Wrench for locknut on end stop adjusting screw. X 380000263 Draft control setting tool. X 380000264 Position and draft control setting tool. 380000266 Lift arm speed adjusting pin seal installer. 380000238 Hook lifting adapter. 380000224 Sling hook. 293449

Adapter of hydraulic pressure check kit.

380000240 Hydraulic pressure check kit. 380000275 Control pilote valve seal guard. X 380000274 Control pilote valve check adapter.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 SECTIONAL VIEWS

TRE0700A

1 Cross Sectional View of Lift Assembly C1 Lift cap screws C2. Thrust plate cap screws G = 0.2 to 1.4 mm (0.008 - 0.055 in). Shaft end float. 1. Inner arm 2. Cross shaft 3. Link arm. 4. Arm thrust plates 5. R.H. Seal 6. L.H. Seal 7. R.H. Bushing

8. 10. 11. 12. 13. 14. 15. 16. 18. 19.

L.H. Bushing Thrust washers Top link support Piston rod pin Travel limit adjusting screw Travel limit adjusting screw locknut Travel limit control rod Control valve link pin Draft control inner lever pivot Set screw

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

TRE0701A

2 Cross-Sectional View of Hydraulic Lift Control Valve Block a. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13.

Detail of O-ring and back-up ring Spool valve Spool valve seat Plug Spool return spring Valve plunger Plunger spring Plug Piston seat Piston Spring cup Draft sensitivity adjustment valve spring Draft sensitivity adjustment valve Plug

14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 30. 31. 32. 33.

Ring Cylinder safety valve Response control valve Arm lowering speed control valve Ball Response control valve adjusting pin Delivery connection Check valve spring Check valve Check valve seat Retaining ring Roll pin Back-up ring O-ring

NOTE: Install O-ring 33 and back-up ring ring 32 as shown in detail (a) using protection device 380000266 and by heating ring 32 in oil at 50 Â°C (122 Â°F). Take care to install ring 32 with flat surface facing upwards and concave surface facing O-ring 33. Take necessary precautions not to damage them.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

8 1

13 11 12 29 30

27 26

25 33

21 22

TRE0711A

b 3

Auxiliary Control Valves - Section views a. Auxiliary control valve configured for operation of single/double-acting cylinder. b. Auxiliary control valve configured for operation of double-acting cylinder with float control and automatic detent release. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14.

Cover Distance piece Spool Check valve Housing Seal Seal Single/double-acting operation switching valve Single/double-acting operation adjusting spool Valve body Spool return spring Spring cup Seal Seal

15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33.

Control lever Control lever support Tapered needle Seal Spring Detent balls Detent ball support Seal Internal plunger Spring Cover Detent release pressure adjuster screw Spool return spring Spring cup Seal Seal Detent notch body Detent screw locknut Circlip

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

TROUBLESHOOTING Problems The lift does not raise.

The lift operates jerkily.

The lift raises too slowly.

Possible Causes

Remedies

Oil filter clogged.

Replace filter.

Control valve jammed in discharge position.

Release control valve.

Hydraulic pump defective.

Overhaul or replace pump.

Oil filter clogged.

Replace filter.

Air has got into the pump suction line.

Check that the couplings are airtight and the seals are effective.

Oil filter clogged.

Replace filter.

Oil leaking past piston seals or Replace all defective seals. seals on discharge fitting to cylinder, with consequent loss of pressure.

The lift operates too quickly.

The lift operates too slowly.

Hydraulic pump defective.

Overhaul or replace pump.

Foreign matter between the ball and its seat on the discharge control valve.

Take off the valve, remove the foreign matter and inspect the oil filter.

Discharge control valve ball seal defective.

Replace discharge control valve.

Discharge control valve piston jammed.

Take off the valve and free the piston.

Discharge ports on the discharge Take off the valve, unblock the holes and inspect the oil filter. control valve blocked. Discharge control valve piston jammed.

Take off the valve and free the piston. (continued)

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 TROUBLESHOOTING Problems

Possible Causes

The lift is unable to keep the load Defective seal on check valve. raised (with the engine running, the load moves up and down rhythmically; with the engine Oil leaking past the seals on the turned off, the load lowers). control valve block pin seat.

Take off, check, clean and if necessary replace the parts concerned. Replace seals.

Control valve block pin seal defective.

Take off and clean the seal and replace the control valve block pin and its seat if defective.

Oil leaking past the lift piston seal or the seals on the cylinder oil discharge fitting.

Replace the seals.

Defective seal or cylinder safety valve set to very low value.

Replace the valve.

The pressure relief valve cuts in Lift arm travel set incorrectly. when the lift arms reach their completely raised position. Lift has poor lifting capacity.

Remedies

Pressure relief valve set incorrectly.

Set correctly.

Replace the valve.

Cylinder safety valve set incorrect- Replace the valve. ly. Poor pump efficiency (generally accompanied by a considerable increase in lift time).

Overhaul or replace the pump.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

OVERHAUL MECHANICALLY CONTROLLED HYDRAULIC LIFT Removal

DANGER Lift and handle all heavy parts using suitable lifting equipment with sufficient hoisting capacity. Check that the assemblies or parts are held firmly and supported by suitable slings and hooks. Make sure nobody is standing near to the load.

To remove the hydraulic lift assembly from the rear transmission casing, proceed as follows. 1. Disconnect the negative cable (1) from the battery.

TRE0035A

2. Remove the top link (1).

TRE0112A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3. Remove the bolts (1) and use a chain and hoist to remove the pick-up hitch hook (2) from the PTO box.

2 1

TRE0113A

4. Remove the split pins and withdraw the shafts (1). Remove the lift rods (2) and the lateral stabilizer struts (3).

1 2 3

TRE0114A

5. Remove the bolts (1) and remove the bracket (2) supporting the RH lift rod adjusting crank.

TRE0125A

6. Disconnect the auxiliary control valve pipes from the support plate (2).

25537

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

7. Remove auxiliary control valve pipes (2) from their support (1).

1 TRE0140A

10 8. Remove the two bolts (1) and the seven-pole socket (2).

1 2

TRE0122A

9. Remove the bolts (1) and remove the support (2).

1 2

TRE0115A

10. Remove the bolt (1) and disconnect the breather pipe.

TRE0126A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

11. Remove the electric socket (1).

TRE0123A

12. Remove the retaining springs (1) and detach the two control rods (2) from the lift levers.

2 1

TRE0127A

15 13. Remove the Fast Raise/Lower control device rod (1).

TRE0117A

14. On models with cab, connect a suitable hoist (2) to the cab lifting hooks (1) and apply tension to the hoist.

TRE0137A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

15. Remove the two cab front securing bolts (1).

TRE0129A

16. Remove the two cab rear securing bolts (1). Raise the cab approximately 5-6 cm (2-2.5 in) and place wooden blocks (1) between the cab upright and the housing. Lower the hoist so that the cab rests securely on the wooden block.

TRE0128A

17. Remove the pipes on the lift (1) and the control valve body (2).

2 TRE0138A

18. Remove the bolts (1) that secure the hydraulic lift assembly to the transmission casing.

25556

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

19. Attach tool 380000237 (1) on the lift and tighten the four bolts (2).

25558

20. Attach tool 380000224 (1) onto tool 380000237 (2). Attach the hoist to tool 380000224. Raise the hydraulic lift assembly approximately 2 centimeters (1 in) and pull backwards enough to clear the breather pipe (3).

3 25559

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Installation Install the hydraulic lift assembly to the transmission casing as follows.

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. 1. Clean and degrease the mating surfaces thoroughly and apply a strip of sealing compound of about 2 mm (0.0787 in) diameter as shown in fig. 24. 2. Apply the torque settings listed on page 7. 3. Using tools 380000224 and 380000238, install the hydraulic lift assembly to the transmission casing and tighten the bolts securely. 4. Insert the electric leads into the clips on the lift body. 5. Install the lift control pipe. 6. Raise the cab enough to remove the wooden blocks and tighten the bolts to secure the cab. 7. Install the oil filler pipe. 8. Connect the Fast Raise/Lower device control rod. 9. Connect the lift control levers to the linkages. 10. Install the windshield washer tank and transmission breather pipes onto the cab upright. 11. Install the top link support bracket and the quickrelease support plate for auxiliary control valves. 12. Install the seven-pole socket, the ground leads, the quick-release to auxiliary control valve pipes to the support. 13. Install the additional control valve rods and the PTO operating mode rod. 14. Install the ground lift control lever. 15. Install the lift rods and the lateral stabilizer struts. 16. Install the pick-up hitch hook and the top link. 17. Connect the negative cable to the battery.

26295

24 Sealing compound application for installing the hydraulic lift assembly on the transmission casing.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Disassembly

DANGER Handle all parts with the utmost care. Do not place your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

To disassemble the hydraulic lift, proceed as follows. 1. Position the hydraulic lift on a rotating type stand (1). TRE0143A

25 2. Remove the bolts (1) and remove the control valve block (2).

1 2

3 TRE0133A

3. Remove the two cylinder securing bolts positioned outside the cylinder body. Turn the lift assembly and unscrew the lateral bolt (3).

4. Remove the bolts (1) that secure the internal linkage (2) to the lift cylinder.

3 25626

5. Remove the lift cylinder (1) and piston.

25627

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 6. Remove the retaining pin from the internal draft lever. Remove the nut (1), then remove the unit complete with internal linkages and the FAST RAISE LOWER device control lever.

TRE0134A

7. Remove the circlip and the internal position control lever (1). Remove the nuts (2) and remove the spring and fixing bracket (4).

8. Remove the circlip, lever (3), friction discs, lever (5) and stud bolts.

TRE0132A

9. Loosen the eccentric pin (2) retaining bolt (1). Remove the eccentric pin and internal linkage.

10. Remove the bolt (3), washer (4), lift arm (5) and the thrust washer. Repeat on the other lift arm.

2 3 4 5 25631

11. Remove the crimping on the internal arm locking bolt (1) and remove the bolt, shaft (2) and the seals (3).

25632

3 32

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

12. Remove the piston (2) from the cylinder (1).

NOTE: If necessary, use compressed air to force the piston out of the cylinder.

WARNING

Wear a protective face shield when using compressed air to remove the piston. 26297

13. Using striker tool 380000260 (1), replace the bearings in the internal draft control lever (2). 14. Using striker tool 380000261, replace the control valve block control lever bearings.

Assembly Assemble the hydraulic lift as follows.

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. 1. Insert the piston (1) into the cylinder (3), using tool 380000225.

26298

25634

2. Install the lift arm shaft (2) and the internal arm (1) inside the lift housing, ensuring to match up the reference marks, as shown. Tighten the securing bolt.

1 2 26299

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 3. To avoid damaging the internal seal lips, use a flexible brass sheet (1) of size 200 x 90 mm (7.8 x 3.5 in) and thickness 0.05 - 0.1 mm (0.002 0.004 in). Roll the sheet up and insert the seal inside. Position the unit on the spline and push the seal manually into the seat, then remove the sheet.

2 26300

4. Using striker tool 380000262 (1) to install the seals into the seats on the lift arm shaft.

26326

5. Install the lift arms (1) on the shaft, ensuring to match the reference marks, as shown. Tighten the bolts.

25633

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

6. Install the internal linkages and the corresponding eccentric pin. Fasten the eccentric pin by tightening the securing bolts. 7. Install the control levers, friction discs, snap rings, and stud bolts. 8. Install the spring and the bracket which secures the lever unit. 9. Install the internal position control lever. 10. Install the internal linkages and the Fast Raise/ Lower control device. 11. Install the cylinder with piston. Tighten the bolts. 12. Install the internal linkages and connect to the cylinder. 13. Clean the mating surfaces thoroughly and apply a 2 mm (0.0787 in) diameter strip of sealing compound to the lift box, as shown in fig. 40. 14. Install the hydraulic control valve block on the lift housing and tighten the bolts. Make the following adjustments. 15. Proceed with Mechanically Operated Hydraulic Lift Adjustments.

TRE0705A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

ADJUSTMENTS Adjusting the HPL on a Workbench NOTE: The following procedures describe adjustment of the hydraulic lift with the lift assembly [cover] removed from the tractor. IMPORTANT: Follow the procedures in the order specified to prevent incorrect adjustment of the hydraulic lift. HPL on the Workbench 1. Attach the hydraulic lift cover (1) to a rotary stand (2).

25624

41 2. Remove the retaining bolts (1) and the control valve (2) from the lift assembly.

25625

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

3. Place the fast raise/lower control device in the deselect position. The recommended procedure for holding the fast raise/lower control in the deselect position is to remove the return spring (1) from the internal linkage mechanism. An alternate method is to tie the external lever (3, figure 42) in the vertical position.

NOTE: Unless otherwise noted, ensure the fast raise/lower control remains in the deselect position throughout the adjustment procedure. 10050124

43 NOTE: Adjusting the hydraulic lift internal linkages will require the use of special tool 380000264. The tool mounts to the lift cover at the point where the control valve is removed. It is important to understand the use of this tool to correctly adjust the linkage. The tool consists of a spring loaded plunger (1), which aligns with an inner reference surface (2), or outer reference surface (3), depending on the adjustment being performed. At location (4) next to the plunger, an air fitting provides a means of attaching compressed air to the tool, which will be used for forcing the lift cylinder piston out of the housing during adjustment procedures.

2 44

Position Control 4. Install special tool 380000264 (1) where the control valve was removed from the lift cover as shown in the figure. Tighten the mounting bolts (2).

1 10050134

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 5. Move the position control lever (1) completely forward, against the spacer (2) of the lever support bracket. 6. Move the draft control lever (3) completely rearward against the spacer (4) of the lever support bracket.

4 1

10050122

3 46

NOTE: The lift arms must be in the fully raised position (1) (arms perpendicular to the lift cover as shown).

10050138

1 47

NOTE: When the lift arms are in the fully raised position, the cross-shaft crank (1) will be in contact with the rear portion of the lift cover (2).

10050106

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

7. Use special tool 380000267 (1) for the following adjustment:

25637

49 8. Loosen the maximum height adjuster lock nut (1) and unscrew adjusting bolt (2) until it no longer contacts lever (3).

1 4

25638

50 9. Loosen locknut (1) of the position control adjuster and turn the adjuster (2) to align the spring loaded plunger (1, figure 52) of tool 380000264 with the outer reference surface (2, figure 52) of the tool. Tighten the adjuster locknut when done.

2 10050125

51 Special Tool 380000264 1.

Spring Loaded Plunger

Outer Reference Surface

1 10050131

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 NOTE: This corresponds to a distance of 82.0 to 82.1 mm (3.2283 to 3.2322 in) between the end of the control lever (1) and the front plane of the lift body, which is represented by measurement (L1) with a force applied of 40 to 45 N (9 to 10 lb) on the end of the lever (F1).

31 1 3

25638

53 10. Rotate the position control lever (1) completely rearward (clockwise) against the lever support bracket spacer (3). Ensure the draft control lever (2) is completely rearward (clockwise) against the lever support bracket spacer (3).

3 1 2 10050154

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

11. Position the lift arms in the fully lowered position (arms (1) are parallel with the lift cover and the cross-shaft crank is away from the rear of the lift cover).

1 10050133

55 12. Ensure the spring loaded plunger (1) is flush or withdrawn from the inner reference surface (2) of tool 380000264. Special Tool 380000264 1.

Spring Loaded Plunger

Inner Reference Surface

10050134

56 NOTE: This corresponds to a distance greater than 86.5 mm (3.4055 in) between the end of the control lever (1) and the front plane of the lift body, which is represented by measurement (L1) with a force applied of 40 to 45 N (9 to 10 lb) on the end of the lever (F1).

1 3

25638

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 Lift Arms Max Raise Position 13. Move the position control lever (1) fully forward (counterclockwise) against the control lever support bracket spacer (2), and the draft control lever (3) fully rearward (clockwise) against the control lever support bracket spacer (4).

4 1

10050122

3 58

14. Position the lift arms in the fully raised position (lift arm cross-shaft crank contacts the rear portion of the lift cover) and the lift arms (1) are perpendicular to the lift cover.

10050138

WARNING When using compressed air, wear all required safety clothing such as goggles or face shield.

WARNING When using compressed air, keep all fingers and hands away from moving parts. 15. Connect a supply of compressed air with an adapter (1) to special tool 380000264. Inject compressed air into the cylinder sleeve to force the piston through the lifting stroke and maintain this position with the compressed air.

10050148

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

16. Using special tool 380000267 (1), perform the following adjustment:

25641

61 -

Loosen locknut (1) and rotate the maximum height adjuster (2) until the spring loaded plunger (2, figure 60) is flush or retracted a distance of 0.5 mm (0.0196 in) from the inner reference surface (3, figure 60) of tool 380000264.

NOTE: This corresponds to a distance of 86.3 to 86.7 mm (3.3976 to 3.4133 in) between the end of the control lever (3) and the front plane of the lift body, which is represented by measurement (L1).

1 4

17. Tighten locknut (1) to a torque of 15 Nâ&#x2039;&#x2026;m (11 ft-lb). 18. Remove the compressed air source from tool 380000264. Draft Control 19. Disassemble the upper end of the draft control rod (1), located within the transmission housing.

25638

10050150

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

20. Connect the upper rod (1) with the short accessory rod (2) from special tool 380000263 and the lower draft control rod (3), located in the transmission housing. Do not tighten locknuts.

21. Place the tool with joined rods on a flat level surface and adjust the rods to the height of the upper surface of the tool as shown. When finished, secure the rods by tightening the locknuts.

1 3 64

22. Rotate the draft (1) and position (2) control levers fully rearward (clockwise) against the lever support bracket spacer (3).

10050132

65 23. Install special tool 380000263 (1) on the lift cover and secure with retaining bolts (2) as shown.

1 2

2 10050157

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

24. Remove the eccentric pin locking bolt (1), bracket (2) and set-screw (3).

1 3

26350

67 25. Rotate the eccentric shaft until the cam on the shaft faces horizontally towards the rear of the lift. 26. Rotate the adjusting bolt (1) on tool 380000263 until the spring loaded plunger on tool 380000264 is flush with the inner reference surface (refer to figure 60). 27. Rotate the eccentric shaft to retract the plunger of tool 380000264 as far in as possible.

1 10050161

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 28. Again turn the screw (2) figure to adjust the internal draft control lever (3) until the end of the plunger (figure ) is flush with the inner reference surface (3) of tool 380000264.

1 2 3

25642

TRE0709A

70 29. Rotate the eccentric shaft again until the spring loaded plunger (1) of tool 380000264 is flush with the outer reference surface (2).

1 10050131

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

30. Measure distance L2 between the upper surface of the tool (1) and the top of the rod assembly (1) with a depth gauge. This distance must be 22.9 to 23.1 mm (0.902 to 0.909 in).

NOTE: The draft control lever must be in the fully rearward position, and the spring loaded plunger of tool 380000264 must be flush with the outer reference surface before checking the measurement of 22.9 to 23.1 mm (0.902 to 0.909 in).

26348

72 31. If the measured value does not fall within this specification, adjust using clevis end (1). If the specified measurement of 22.9 to 23.1 mm (0.902 to 0.909 in) is within one-half turn of the turnbuckle, it can be corrected with the draft control linkage adjustment after installing the lift cover on the transmission.

32. Attach the fast raise/lower control spring. 33. Remove special 380000264.

tools

380000263,

and 10050162

73 34. Replace the O-rings and seals on the control valve and install the control valve on the lift cover. Tighten the retaining bolts to a torque of 26 Nâ&#x2039;&#x2026;m (19 ft-lb). 35. Install the upper rod (1) on the draft control rod linkage (2) on the transmission. Adjust the length of the upper rod until the rod protrudes 18.3 to 18.5 mm (0.720 to 0.728 in) above the surface of the transmission (L6) as shown. Tighten the lock nut.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

NOTE: Check that the flex bar in the transmission is not bent by rotating the bar with the draft control vertical rod installed in the transmission housing. A bent flex bar will cause the draft control rod to move up and down while it is rotated.

1 2

36. Position special tool 380000263 (1) on a level surface and use a micrometer depth gauge (2) to measure distance (L5) between the point where the tool rests on the reference surface and the point where the micrometer gauge rests on the tool. Record this distance. 75 37. Position tool 380000263 over the top of the draft control rod above the transmission housing, and secure the tool to the housing with the two retaining bolts (4).

1 2

38. Subtract 18.4 mm (0.724 in) from the recorded measurement L5.

Example: L4 = L5 – 18.4 mm (0.724 in)

where: L5 = 45.1 mm (1.778 in) Protrusion = 18.4 mm (0.724 in) and 45.1 mm – 18.4 mm = 26.7 mm (1.778 in – 0.724 in = 1.054 in) L4 = 26.7 mm (1.054 in) 39. Set the depth gauge (2) to the L4 calculation and adjust the draft control rod (3) until the tip of the upper rod contacts the end of the depth gauge on the tool. Tighten the locknut. 40. Install the lift cover on the transmission. Refer to this chapter.

4 76

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Installation To reinstall the hydraulic lift to the transmission-gearbox casing, proceed as follows.

WARNING Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS. 1. Before reassembling the hydraulic lift on the rear transmission casing, carefully clean and degrease the mating surfaces, then apply sealing compound (approx. 0.7874 in (2 mm)) along the marked line shown in figure 77. 2. Using tools 380000224 and 380000238 install the hydraulic lift on the transmission-gearbox casing and secure with the relative bolts. 3. Insert the electrical cables in the clip on the lift body. 4. Install the lift control pipe. 5. Install the oil filler pipe. 6. Connect the fast raise/lower control tie-rod. 7. Connect the lift levers to the relative tie-rods. 8. Connect the PTO revs counter electrical connection. 9. Attach the fuel tank and transmission-gearbox breather pipes to the cab upright. 10. Assemble the three-point top link and the quickfit coupling support plate for the auxiliary control valves. 11. Install the two pole socket, seven pole socket, ground connections and quick-fit couplings. 12. Assemble the right-hand vertical tie-rod adjustment unit. 13. Assemble the vertical tie-rods and anti-swing rod. 14. Install the towing hook and the three-point top link. 15. Adjust the HPL. Refer to â&#x20AC;&#x153;Adjusting the HPL on the Tractor.â&#x20AC;?

26295

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Position Control Linkage 1. Move the position control lever (1) fully forward on the quadrant and check that the distance (L) is between 15 and 20 mm (0.59 - 0.78 in). L 1

TRE0108A

2. Move the external position control lever (1) fully rearward, against the spacer. 3. Connect the control linkage and adjust the length, if necessary. 4. Fasten the linkage using the lock nuts.

TRE0121A

Draft Control Linkage 5. Start the engine and run at medium speed. 6. Allow the hydraulic oil to warm to 30 - 40Â°C (86 - 104Â°F). Then proceed as follows: 7. Move the position control lever (1) fully forward on the quadrant and the draft control lever (2) to a distance (L1) of 15 - 20 mm (0.59 - 0.78 in) from the beginning of the slot. 8. Move the draft control lever (2) fully back against the spacer.

TRE0121A

9. Connect the control linkage and adjust the length if necessary.

TRE0121A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

10. Move the draft control lever (2) to a distance (L2) of 105 - 115 mm (4.13 - 4.52 in) from the beginning of the slot and check that at this position the arms start to rise. If arms do not, adjust the eccentric pin, to restore this distance.

2 L2

11. Fasten the eccentric pin using the securing bolt. 1

82 Fast Raise/Lower Control Device

12. Move the position control lever (1) and the draft control lever (2) fully forward in the sector.

TRE0116A

13. Raise the lift arms by means of the lever (1).

TRE0017A

84 14. Tighten the nut (1) fig. 85, until the arms lower. 15. With the lever (1) fig. 84, still in the same position, unscrew the nut (1) fig. 85, until the arms begin to rise. 16. Remove the nut (1) by another 1.5 turns.

17. Using the levers (1) and (2) fig. 84, lower and raise the arms a few times to ensure that the system is operating correctly.

TRE0117A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

LIFT PRESSURE RELIEF VALVE Installation Auxiliary control valve blocks. The lift pressure relief valve (1) is located as shown in fig. 86). If defective, remove and change the valve.

TRE0139A

Calibration Proceed as follows. 1. Run the engine until the oil reaches a temperature of about 50Â°C (122Â°F).

2. Insert a 0 - 250 kg/cm2 (3500 psi) scale pressure gauge supplied with kit 280000240, into a quickfit coupling. 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 186 - 191 bar (2697 - 2770 psi). If the valve setting does not correspond to the prescribed value, it is best to change it immediately. However, 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.

TRE0142A

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Pressure relief valve section 1. 2. 3. 4. 5. 6. 7.

One-way valve Additional control valve body Pressure relief valve body Valve spring Locknut Adjustable needle (4 mm wrench) Plastic sealing

88 NOTE: The pressure relief valve setting can be bench tested as follows:

Install the pressure relief valve (1) on the valve union 380000217 (2) and connect the union to the hand pump 38000015 (3). Operate the hand pump (3) and check that the pressure relief valve opens at a pressure of about 186 - 191 bar (2697 - 2770 psi). IMPORTANT: During assembly, the pressure relief valve is calibrated using oil flow and the check using hand pump 380000215 is to be considered only approximate. It is therefore advisable to check the pressure relief valve setting with the valve fitted on the tractor as described above.

25720

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

LIFT CONTROL VALVE BLOCK Disassembly Proceed as follows.

WARNING

Handle all parts with the utmost care. Do not place your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and protective footwear.

1. Before removing the control valve, first remove the transmission cover (1).

TRE0104A

2. Before disassembly, thoroughly clean the surfaces of the control valve block. Lock the control valve block in a vice.

3. Remove the cap (1) and remove the spring (2) and the control valve (3).

25707

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

4. Remove the cylinder safety valve (4) and remove the arm lowering speed adjustment valve (3), the spring (2) and the pin (1).

25709

5. Remove the check valve union (1), spring (2) and ball (3).

25711

6. Remove the control valve block pin (1) and remove the seat (3) and the spring (2).

25713

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 7. Check the wear of the seals on the control valve block pin seat. If damaged, replace them using protection device 380000275 (1), following the instructions given on page 8.

47 1

8. Check the efficiency of the control valve block pin as follows.

25714

9. Install the control valve block pin (2) complete with seat (3) on the tool 380000274 (1).

25715

10. Install 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.

25716

11. Install tool 380000274 (2) on the hand pump 380000215 (3), supplied with AMBRA MULTI G oil. Connect a dial gauge (1) and secure it with its screw.

1 2 3

25717

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

12. Operate the hand pump and at the same time tighten screw (1) on the tool until oil stops flowing out through the control valve block pin seat outlet. 13. Zero the dial gauge. 14. Tighten the screw (1) on the tool further to move the control valve block pin by 1.8 - 2 mm (0.070 - 0.078 in), using the dial gauge to read this distance.

25718

15. Operate the hand pump until the oil in the system is at an initial pressure of 245 bar (3550 psi). Using the pressure gauge, check that it takes more than six seconds for the pressure to fall from 196 bar (2840 psi) to 98 bar (1421 psi). If it takes less than this, replace the control valve block pin. Bear in mind that this part is supplied together with its seat.

25719

100

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 16. Install the cylinder safety valve (1) on the valve union 380000218 (2) and connect it to the hand pump 380000215 (3).

49 3

17. Operate the hand pump (3) and check that the cylinder safety valve opens at a pressure of 210 - 215 bar (3045 - 3118 psi). If the valve setting does not correspond to the specified value, it is best to replace the valve straight away. If necessary, however, it can be adjusted by turning the threaded cap using spanner 380000230. Tighten to increase the valve setting value, or loosen to decrease the value. Assembly

WARNING Always use appropriate tools to align fixing holes. NEVER USE YOUR FINGERS OR HANDS. â&#x20AC;&#x201D; Refer to the illustrations on page 11 for the orientation of the various components: â&#x20AC;&#x201D; Apply the torque settings listed on page 7. 1. Install the complete control valve block pin. 2. Install the check valve. 3. Install the cylinder safety valve. 4. Install the control valve. 5. Install the complete pressure control valve. 6. Install the cover on the control valve block.

25720

101

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

24622

102 High-Pressure (Lift) Pump Components 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Front cover Cover seals Pump body Gear support Driven and driving gear shafts Gear support Bushing Control side cover Driving shaft seal Spacer

HIGH-PRESSURE (LIFT) PUMP Disassembly Proceed as follows: 1. Remove the cover fastening nuts (20), then the bolts (15) and the safety washers. 2. Remove the nut (14) that fastens the sleeve to the pump driving shaft and the safety washer. 3. Remove the front cover (8), the circlip (12) and the seals (9 and 11). 4. Mark parts 3, 4, 5 and 6 to enable them to be remounted in the same position if they are in good condition.

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

Driving shaft seal Snap ring Safety washer Nut Bolt Washer Key Bushing Safety washer Nut

5. Remove the supports (4 and 6) and the gears (5) from the rear cover (8) and the pump body (3). 6. Remove the seals (2) and the anti-extrusion rings. Inspection and Repair 1. Check that the gear contact surfaces are flat and perpendicular to their supports. Insert a thin layer of carbon black. Small rough spots can be removed using extremely fine and well lubricated abrasive paper.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

2. Check that the axial play of the gear-support unit in the pump body is 0.090 - 0.160 mm (0.003 0.006 in). The distance (2) must be 0.090 - 0.160 mm smaller than the distance (1). 3. If necessary, true the flat surfaces involved using lubricated abrasive paper to remove extremely small quantities of material. Ensure that axial play is still within the limits of 0.090 - 0.160 mm (0.003 - 0.006 in).

4. Clean all constituent parts thoroughly. 5. Replace the seals (2, 9 and 11). 6. Lubricate the parts with the same oil as the system. Install the pump, referring to fig. 102 and proceed as follows: 25227

Assembly 1. Perform Disassembly operations in reverse order; NOTE: Always ensure maximum cleanliness to prevent foreign matter from entering, as this could damage the pump. 2. Install previously marked parts (3), (4), (5) and (6) fig.102; see procedure on page 50. 3. Mount the gear supports (4) and (6) fig. 102, in the pump body. Mount them with the fittings on the external circumference matched up with the discharge pipes and the front faces with lubrication millings in contact with the gears; 4. Install the plastic anti-extrusion rings on the seals (2) fig. 102: 5. Mount the seals (9) and (11) fig. 102, on the control side cover (8), complete with spacer (10). Mount them so that the cavity is between the seal lips on the opposite side from this spacer. Finally fill the cavity with AMBRA GR9.

103

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

CONVERTIBLE SINGLE/DOUBLE-ACTING AUXILIARY CONTROL VALVE Disassembly (valves removed from tractor)

6 5 7 8

1 7

2 9

4 TRE1100A

104 Disassemble the auxiliary control valve into its component parts referring to the sectional views (fig. 3) and the following instructions: 1. Remove cover (3) and O-rings (7). 2. Remove the control lever support (4) and take out the seal (7). 3. Withdraw the spool (8). 4. Remove plug (6) and extract the single/double acting switching valve (5). 5. Remove relief valve block (1) and check valve (2) 6. Remove the valve housing (9) 7. Check the condition of the seals before re-assembly. Assembly 1. Follow the disassembly procedures in reverse order.

WARNING Handle all parts with care. Do not insert fingers or hands between one part and another. Wear suitable safety clothing, i.e., safety goggles, gloves and shoes.

WARNING Always use suitable tools to align holes. NEVER USE YOUR FINGERS OR HANDS.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

CONVERTIBLE SINGLE/DOUBLE-ACTING AUXILIARY CONTROL VALVE WITH FLOAT CONTROL AND DETENT RELEASE Disassembly (valves removed from the tractor)

WARNING Handle all parts with care. Do not insert fingers or hands between one part and another. Wear suitable safety clothing, i.e., safety goggles, gloves and shoes.

WARNING Always use suitable tools to align holes. NEVER USE YOUR FINGERS OR HANDS.

5 7

8 7 8 7

1 2

TRE1101A

4 105

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

Pressure relief valve Check valve Kick-out (detent) and float control assembly Control lever support Single double acting converting valve Oil return valve Spool O-ring kit Kick-out control assembly

Disassemble the auxiliary control valve into its component parts referring to the sectional views (fig. 3) and the following instructions:

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 WARNING

During the overhaul and disassembly-assembly of the units, put special protective devices between the bits of the vice, for preventing any damage to the valve components. 1. Remove Allen screws (1) Fig.106.

TRE1102A

106 2. Remove both covers (1) Fig.107. 1

TRE1103A

107

3. Remove both spacers (1) Fig.108. 1

TRE1104A

108

4. Remove the circlip (1) and take the cover (2) Fig.109 of the valve (Float & detent release).

2 1

TRE1105A

109

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

5. Withdraw the spool assembly (1) Fig.110. 1

TRE1106A

110

6. Complete spool assembly (Float & detent release) is shown at Fig.111.

TRE1107A

111

7. Remove circlip (1) and take off the washer (2) Fig. 112. Disassemble the unit to all its components.

1 TRE1108A

112

8. Disassemble unit (Float & detent release) is shown at Fig.113.

TRE1109A

113

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

9. Remove circlip (1) Fig.114. 1

TRE1110A

114

10. Take off the cover (1) Fig. 115.

TRE1111A

115

11. Remove the spool assembly (Detent release) (1) Fig.116.

TRE1112A

116

12. Remove the nut (1) Fig.117 fixing the assembly. 1

TRE1113A

117

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2 13. Remove the spring and the detent body (1) Fig.118.

57 1

TRE1114A

118

14. Remove the nut fixing the detent body (1) Fig.119

TRE1115A

119

15. Complete spool assembly (Detent Release) is shown at Fig.120.

TRE1116A

120

16. Remove oil return valve (1) Fig.121. 1

TRE1117A

121

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

17. Take off oil return valve (1) Fig.122.

TRE1118A

122

18. Remove relief valve (1) Fig.123. 1

TRE1119A

123

19. Withdraw relief valve (1) Fig.124. The relief valve can be checked when the engine is running. When the relief valve is tested as explained Section 35 Chapter 1 the pressure gauge must show a pressure of 186-191 bar (2700-2770 psi). If the valve does not correspond to the prescribed value, it is best to change it immediately.

TRE1120A

124

20. Slacken, single-double acting converting valve (1) Fig.125.

TRE1121A

125

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

21. Remove, single-double acting converting valve (1) Fig.126. 1

TRE1122A

126

22. Take off the ball of, single-double acting converting valve (1) Fig.127. 1

TRE1123A

127

23. Loosen and remove the allen screws (1) that secure the cover (2) Fig.128.

TRE1124A

128

24. Remove the cover (1) and the spacer (2) Fig.129.

25. Inspect all seals before reassembly.

Assembly 1. Follow the disassembly procedures in reverse order.

TRE1125A

129

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

Double-acting auxiliary control valve with float control and automatic detent release. Disassemble the auxiliary control valve into its component parts referring to the sectional views (fig. 3) and the following instructions: 1. Unscrew the retaining screws and remove the cover (11) and the distance piece.

3. Withdraw the spool (10).

2. Unscrew the retaining screws and remove the control lever support (12) and related seal.

5. Check the condition of the seals before reassembly.

4. Remove the valve housing and extract the check valve and spring.

SPOOL BINDING TEST P

N M

A T A

TRE0719A

130 Auxiliary Control valve spool binding test. Install the auxiliary control valve assembly and the test apparatus as indicated in the diagrams (fig. 130 ) and referring to the following instructions: â&#x20AC;&#x201D; The test is carried out with mineral oil in accordance with DIN 32 norm. Flow rate is the nominal for the valve (for VDM07 it is 50 l/min). Connect line P (pump line) to the inlet port of the valve and close the working ports A and B of each section (see schematic) with plugs. Start the test, increasing the flow coming from the pump until nominal flow plus 25% is reached (in the case of VDM07 it is 75 l/min). With the control lever in the neutral position (mid-position)

the flow goes through the valve from inlet to outlet (tank line) (P) to (T). Now regulate the maximum pressure of the VS (main relief valve) valve inside bank A (in the schematic). This pressure is the maximum pressure that can be obtained with the type of valve and spring used. Now move each single spool in each section. With the ports closed, the pressure will rise until the relief valve opens. In this situation check if spools move to the neutral (central) position without sticking, under the action of springs and flow forces only. The relief valve D, in line before the directional valve, has to substitute the VS in A in case of problems or in case of directional valve without VS.

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

SPOOL LEAKAGE TEST P

A T

TRE0720A

131

Auxiliary Control Valve leakage test After the binding test (with hot oil and valve), measure the leakage rate for each section. It is important to do this with the system hot. Connect working ports A and B of each section to the cylinders (one for each section). Alongside each cylinder lay a ruler to measure the stroke. Supply oil to the cylinder, moving the spool to the working position (oil flowing from A or B) until it reaches the end of its stroke and the main relief valve opens. Now that the oil column is pressurised from the working section to the cylinder allow the lever to return to the neutral position (called 0). The spool closes A and B ports. Now check the position of the cylinder observing the ruler beside it. As the cylinder moves, check the stroke in a fixed time (approximately 60 seconds). From this stroke,

calculate the volume of oil per minute through that section of the cylinder. This check has to be carried out for each section (each spool). After this check, with the pump disconnected, move the spool to its working position: now test the check valve (VU:Check Valve) of the distributor. This valve closes the connection from P to T (N), also the connection P with A or P when B is open (spool in working position). If the check valve is working correctly, the normal flow rate will be seen (the same value observed with spool in the neutral position). If it is see that one or more sections operates more than in a previous check, it means that check valve is not working properly (does not close completely).

SECTION 35 -- HYDRAULIC SYSTEMS -- CHAPTER 2

ADJUSTMENT OF THE AUXILIARY CONTROL VALVE AUTOMATIC DETENT RELEASE PRESSURE After servicing the detent regulating valve or if the control levers and spool are returning to neutral prematurely, the detent regulating valve should be tested as follows: NOTE: Detent release pressure is ONLY adjustable on one spool in the valve that is NOT fitted with float. The spools fitted with kick out and float have no visible means of adjustment. -

Install inlet hose of flowmeter (1) into lift coupler of valve to be tested.

Install return hose from flowmeter into lift coupler of the same valve on tractor.

Ensure load valve on flow meter is fully open;

Start tractor and set engine speed to 1700 rev/min;

Pull lever of remote control valve to be tested, fully rearwards, to extend position.

Adjust load valve (2) on flowmeter until pressure is 80 bar (1161 psi) and run until hydraulic oil is at an operating temperature of 55_C to 65_C (131Â°F to 151Â°F).

With lever of remote control valve to be tested in the cylinder extend position slowly close the flowmeter load valve while observing the flowmeter pressure gauge. The pressure should steadily rise until the detent regulating valve opens, at which point the needle will fluctuate and the handle return to the neutral position. Note the gauge reading immediately

prior to the needle fluctuation. The reading should be within the specified value (1741-1886 psi) 120 bar +10 bar -0 bar. -

If the reading is not to specification adjust the detent pressure as follows: Remove the circlip (33) and the cover (25), (Fig. 3, Page 12) of the valve . Loosen locknut (32) on detent regulating adjuster screw (26). Turn detent regulating valve adjusting screw (26) to change pressure setting.

TRE1126A

2 132

SECTION 41 -- STEERING -- CHAPTER 1

SECTION 41 -- STEERING Chapter 1 -- Steering CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hydraulic Pump C25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydrostatic Power Steering (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Hydrostatic Power Steering (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Steering Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Manual Steering to Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Manual Steering to Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Hydrostatic Steering Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 41 204 34

41 206 20

Hydrostatic Steering Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Steering Cylinder (2WD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Steering Cylinder (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

SECTION 41 -- STEERING -- CHAPTER 1 SPECIFICATIONS

HYDROSTATIC STEERING Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

independent hydrostatic control, feed by hydraulic pump

Oil filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

metal cartridge, built into oil reservoir

Control valve Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

DANFOSS OR ORSTA rotary valve controlled directly from the steering column; the steering continues to function even if the pump is non--functional

Outfit code: -- DANFOSS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- ORSTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OSPC 100 LAG--B 100--LVP16--2

Pressure relief valve setting -- 2WD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . -- FWD models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100 bar (1450 psi) 125 bar (1812 psi)

SECTION 41 -- STEERING -- CHAPTER 1

HYDRAULIC PUMP C25 Pump Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

gear type with oil suction from transmission casing behind timing gear cover

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) . rev/min Corresponding rated output . . . . . . . . . . . . . . . . . . . . . . . . . l/min (gal/min)

C 25 BOSCH driven by timing gears clockwise 1:0.931 2328 26.4 (7)

Bench output at 1450 rev/min and pressure of 153 bar (2219 psi): -- for new or reconditioned pump . . . . . . . . . . . . . . . . . . . . . l/min (gal/min) -- for worn pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . l/min (gal/min) -- test oil temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CÂ° (FÂ°) -- test oil viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15.3 (4.04) 10.7 (2.8) 55 -- 65 (131 -- 149) SAE 20

Diameter of driven and driving gear shafts . . . . . . . . . . . . . . . . mm (ins) Internal diameter of seats in supports . . . . . . . . . . . . . . . . . . . . mm (ins) Clearance between gear shafts and their seats . . . . . . . . . . . . mm (ins) -- maximum clearance due to wear . . . . . . . . . . . . . . . . . . . . . . . mm (ins) Radial clearance of gears in pump body . . . . . . . . . . . . . . . . . . mm (ins) Maximum wear on pump body, suction side, at position of gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) Power Cylinder Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Make . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17.400 -- 17.418 (0.6850 -- 0.6857) 17.450 -- 17.475 (0.6870 -- 0.6879) 0.032 -- 0.075 (0.001 -- 0.0029) 0.1 (0.003) 0.020 -- 0.064 (0.0007 -- 0.0025) 0.1 (0.003) Double acting, located behind front axle WEBER or SIMA or ERBER

Cylinder bore diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) Piston rod diameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins)

48 (1.89) 22 (0.866)

Maximum piston stroke WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins)

215 (8.46) 214 (8.42)

Maximum piston stroke WEBER or ERBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins) SIMA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . mm (ins)

200 (7.87) 194 (7.63)

SECTION 41 -- STEERING -- CHAPTER 1

TORQUE SETTINGS Torque setting PART

Thread Nm

ft-lbs

Bolt fixing hydrostatic steering to tractor . . . . . . . . . . . . . . . . . . . . . . . . .

3/8â&#x20AC;ł--16 UNC

Steering housing cover mounting bolt . . . . . . . . . . . . . . . . . . . . . . . . . . .

M8x1

M 8 x 1*

Steering pump mounting nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M6x1

Pump housing cover nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Thrust sleeve to pump drive shaft nut) . . . . . . . . . . . . . . . . . . . . . . . . . . .

7/16 in --20UNF--2B

Steering cylinder pivot pin nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

294

217

Steering cylinder rod-end to steering arm nut . . . . . . . . . . . . . . . . . . . . .

M 14 x 1.5

147

109

--WEBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

--SIMA cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

--ERBER cylinder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

Capscrew, control valve support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

147

109

Capscrew, LVP safety valve block to body . . . . . . . . . . . . . . . . . . . . . . .

Piston to rod-end nut:

* ORSTA

SPECIAL TOOLS

WARNING The operations described in this section must be performed only with the ESSENTIAL equipment marked with (X). To operate safely and achieve best results, while saving time and effort, essential equipment must be used in conjunction with the special tools recommended below, and tools which you must make yourself and for which you will find the design in this manual.

List of special tools necessary for the various operations described in this section. X 380000307 Hyd. steering rotor retaining lever. X 380000223 Steering wheel extractor. X 380000240 Universal pressure checking kit. X 380000305 Tool for fitting hydrostatic steering toroidal seal. 380000306 Plug for fitting hydrostatic steering rotary valve return springs. X 380000281 Rotoglyd rotor seal installer (Danfoss). 380000210 Dust seal installer (Danfoss). X 380000613 Pressure test fitting. X 380000618 Pressure test fitting.

SECTION 41 -- STEERING -- CHAPTER 1

COMPONENTS

Steering Pump

1. Front cover 2. Cover seals 3. Pump body 4. Gear support 5. Driven and driving gear shafts 6. Gear support 7. Bushing 8. Control side cover 9. Driving shaft seal 10. Spacer

11. Driving shaft seal 12. Snap ring 13. Lock washer 14. Nut 15. Bolt 16. Washer 17. Key 18. Bushing. 19. Safety washer 20. Nut.

SECTION 41 -- STEERING -- CHAPTER 1

24725

Hydrostatic steering -- Control valve components 1. Dust seal 2. Reflux valve balls 3. Reflux valve pins 4. Control valve body, rotary valve and rotary valve seat sleeve 5. Check valve ball 6. Threaded plug of check valve 7. O--ring seal 8. Support ring for O--ring (7) 9. Thrust bearing components 10. Retaining ring for springs (11) 11. Springs for returning sleeve to neutral position

12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.

Rotor control shaft -- sleeve trim pin Cover fixing screws Check valve seat screw Washers Cover O--rings Rotor and fixed ring for rotor Thrust washer O--ring Rotor control shaft Pressure relief valve complete with spring

SECTION 41 -- STEERING -- CHAPTER 1

E D1

H T

50031447

General Hydraulic Diagram H D1 E T P

Control cylinders Hydrostatic steering control valve Filter Oil tank Pump

26 27 M S

Oil in intake line Oil in delivery line from pump Oil Oil at lubrication pressure

SECTION 41 -- STEERING -- CHAPTER 1

TROUBLESHOOTING Refer to Figure 2 for component identification. Problem

Possible Cause

Corrective Action

Oil leaking from hydrostatic steer- O-ring seal defective (7). ing g unit:

Renew the seal and the stop ring using special tool 380000836.

a. Control side.

Tighten the screws to the prescribed torque (24 -- 36 Nm, 17.70 -- 26.55 ft.lbs.).

Screws (13) not sufficiently tight.

b. Cover side

Sealing washers (15) or O-rings Renew the washers and seals. (17) defective. Steering wheel excessively stiff

Hydraulic pump inefficient.

Repair the pump.

Check valve (5) held open by fore- Eliminate foreign bodies and clean igh bodies or open due to ab- the filter; put a new ball into the seat (if missing).. sence of ball. Pressure relief valve (22) incor- Reset the valve. rectly set. Pressure relief valve (22) jammed Eliminate foreign and clean the filter. or held open by foreign bodies. Steering column has become stiff Eliminate the cause. on its bushing due to rusting, seizing, etc. Excessive play of steering wheel. Excessive play between the steer- Renew the worn parts. ing column and the coupling with the rotary valve (4). Excessive play in the coupling be- Renew the worn parts. tween shaft (21) and trim pin (12). Excessive play in the splined cou- Renew the worn parts. pling between the shaft (21) and the rotor (18). Combination of excessive play as Renew the most worn parts. described above. Leaf springs (11) broken or fa- Renew the springs. tigued. The steering wheel turns normally, Inadequate seal of control cylin- Renew the seal. but steering g is: der. a. Slow. Cylinder rod broken. Replace the damaged part. b. No steering Rotor control shaft (21) or pin (12) Replace the damaged part. broken.

With the engine stopped, the Excessive wear between rotor Renew the worn parts. steering wheel can be turned withand fixed ring (18). out turning the wheels. Check valve damaged.

Renew the control valve.

SECTION 41 -- STEERING -- CHAPTER 1

TROUBLESHOOTING Refer to Figure 2 for component identification. Problem

Probable Cause

Corrective Action

Steering wheel jolts, steering Incorrect synchronization of hy- Synchronize correctly. uncontrollable, wheels steering in drostatic steering. Correct the connections. the opposite direction to the Hoses to cylinder reversed. desired direction. The wheels do not maintain the Hydraulic cylinder piston seal Renew the seal. desired alignment and continual worn. correction with the steering wheel Reflux valve (2) damaged or held Eliminate the foreign bodies and is necessary. clean the filter or renew the control open by foreign bodies. valve. Mechanical wear of control valve. Renew the control valve. Neutral phase of hydrostatic Leaf springs (11) for returning steering unobtainable. During sleeve (4) to neutral position manual control, operation is broken or fatigued. normal. When stopping manual Sleeve and rotary valve blocked in control, the steering wheel moves delivery position by foreign on its own or remains stationary, bodies. but steering continues slowly in Crushing of sleeve (4) on rotary the direction first turned valve due to excessive pres(motoring), so the steering wheel sure. must be continually corrected.

Renew the pack of leaf springs.

Front wheel vibration (shimmy).

Bleed the air and eliminate the causes of possible infiltration. Renew the worn parts.

Air pockets in the hydraulic cylinder. Wear of mechanical joints of steering tie rods. Reflux valve (2) damaged or held open by foreign bodies.

Difficulty in steering in general, or Insufficient pressure. in one direction.

Eliminate the foreign bodies and clean the filter. Check the setting of the pressure relief valve (22).

Remove the foreign bodies and clean the filter or renew the control valve.

Check the hydraulic pump and the setting of the pressure relief valve (22). Excessive leakage inside the con- Renew the control valve. trol valve.

SECTION 41 -- STEERING -- CHAPTER 1 DESCRIPTION AND OPERATION

HYDROSTATIC POWER STEERING (2WD) Refer to Figure 4 The rear axle casing functions as a reservoir for the oil used in both the high-pressure system, and the steering system. While the engine operates, the steering pump (6) draws oil from the reservoir through a filter assembly (7), located directly below the pump on the left-hand side of the engine. The filter cleans the oil before it reaches the pump inlet port. The steering pump pressurizes the oil and forces the oil through the outlet to the steering motor control valve (3), mounted at the base of the steering column. Turning the steering wheel clockwise or counterclockwise causes the steering column to rotate the rotary valve (11) within the steering motor (3). Depending on the position of the steering wheel, ducts internal to the control valve direct the flow of oil to the steering cylinder (2). Oil pressure acts on the cylinder piston to extend or retract the piston rod to position the front wheels for a right or left-hand turn. There is no mechanical linkage connecting the steering wheel to the steering cylinder on the front axle.

Thus, the steering system is completely hydrostatic. Operator input at the steering wheel transmits to the front wheels by way of hydraulic oil under pressure. Check valves (4) and (5) maintain the flow of oil in one direction only to prevent back-flow. The anticavitation device (12) ensures that the steering system receives priority over the low-pressure circuit by providing a sufficient amount of oil as needed. A relief valve (9) protects the system from over-pressurization. Unlike the FWD models, which consist of two steering cylinders, the 2WD steering system contains only one steering cylinder mounted on the right-hand side of the front axle. The cylinder transmits motion to the front left wheel through a rod assembly, mounted on each end of the wheel spindles, and aft of the front axle. The 2WD steering system also contains a balancing valve (1), which counteracts the force of the larger piston area to smaller rod end area in the steering cylinder to prevent the front wheels from drifting to the left.

SECTION 41 -- STEERING -- CHAPTER 1

Static oil Pump supply oil Return to sump oil Intake oil Oil in balancing pressure

10 4

MDE0716A

Hydrostatic Power Steering Oil Flow (Neutral) (Models with 2WD) 1. 2. 3. 4. 5.

Balancing valve Steering cylinder Steering motor control valve Check valve Check valve

6. 7. 8. 9. 10. 11. 12.

Steering/low-pressure pump Filter assembly Return to rear transmission Pressure relief valve Valve seat sleeve Rotary valve Anticavitation device

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC POWER STEERING (MFD) Refer to Figure 5 The rear axle casing functions as a reservoir for the oil used in both the high-pressure system, and the steering system. While the engine operates, the steering pump (6) draws oil from the reservoir through a filter assembly (7), located directly below the pump on the left-hand side of the engine. The filter cleans the oil before it reaches the pump inlet port. The steering pump pressurizes the oil and forces the oil through the outlet to the anticavitation device (5), and on to the steering motor assembly (2), mounted at the base of the steering column. Turning the steering wheel clockwise or counterclockwise causes the steering column to rotate the rotary valve (11) within the steering motor (2). De-

pending on the position of the steering wheel, ducts internal to the control valve direct the flow of oil to the relative steering cylinder (1). Oil pressure acts on the cylinder piston to extend or retract the piston rod to position the front wheels for a right or left-hand turn. There is no mechanical linkage connecting the steering wheel to the steering cylinders on the front axle. Thus, the steering system is completely hydrostatic. Operator input at the steering wheel transmits to the front wheels by way of hydraulic oil under pressure. Check valves (3) and (4) maintain the flow of oil in one direction only to prevent back-flow. The anti-cavitation device (5) ensures that the steering system receives priority over the low-pressure circuit by providing a sufficient amount of oil as needed. A relief valve (9) protects the system from over-pressurization.

SECTION 41 -- STEERING -- CHAPTER 1

Static oil Pump supply oil Return to sump oil Intake oil Oil in balancing pressure

11 2

10 3 9 4 5

8 7

50044742

5 Hydrostatic Power Steering Oil Flow (Neutral) (Models with FWD) 1. 2. 3. 4. 5. 6.

Steering cylinders Steering motor control valve Check valve motor Check valve Anticavitation device Steering/low-pressure pump

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

Filter assembly Return to rear transmission Pressure relief valve Valve seat sleeve Rotary valve Anticavitation valve

SECTION 41 -- STEERING -- CHAPTER 1

14 OPERATION

Steering Right When the steering wheel is turned in a clockwise direction, the springs deform, allowing the valve to rotate in relation to the sleeve. Under these conditions the following occurs: -- The internal passages on parts, which were previously communicating in the neutral phase, become misaligned and the oil outflow is interrupted. -- The alignment with the same number of ducts, that are connected with the compartments on the rotor in the pump suction phase and in the delivery phase of the steering cylinders, allow turning to the right.

Manual Steering to Right In the event of power steering pump failure or insufficient oil pressure, turning is possible manually. When the steering wheel is turned in a clockwise direction, the power steering control valve internal rotor operates as a hand pump, directing the oil to the rod side of the cylinders, allowing manual turning to the right. Manual Steering to Left When the steering wheel is turned counterclockwise, the internal power steering control valve rotor operates as a hand pump (as previously described), directing the oil to the cylinder piston side, allowing manual turning to the left.

Steering Left When the steering wheel is turned counterclockwise, the internal grooves on parts and the delivery to the steering cylinder are inverted, allowing turning to the left.

Static oil Pump supply oil Return to sump oil Intake oil Oil in balancing pressure

50044743

Hydrostatic Power Steering Oil Flow (Turning) (Models with FWD Shown -- Similar on 2WD) A. Right-hand turn

B. Left-hand turn

SECTION 41 -- STEERING -- CHAPTER 1

HYDROSTATIC STEERING CONTROL VALVE Removal

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. To remove the hydrostatic steering control valve, proceed as follows: 1. Disconnect the negative cable (1) from the battery. 2. Drain the oil from the steering system.

25621

3. Open the engine hood (1).

TRE0033A

8 4. Disconnect the oil pipes (1) from the steering control valve (2).

2 TRE0434A

5. Remove the steering wheel retaining nut (1) and remove the steering wheel with hand throttle lever.

25758

SECTION 41 -- STEERING -- CHAPTER 1

6. Remove the four securing screws (1) from the instrument panel (2).

25759

11 7. Disconnect the electrical leads (1) from the rear of the instrument panel. Unscrew the tachometer cable (2). Remove the instrument panel.

2 TRE0435A

12 8. Unscrew the rear hood screws (1).

TRE0436A

13 9. Remove the complete rear hood.

TRE0437A

SECTION 41 -- STEERING -- CHAPTER 1

10. Remove the mounting bolts and the steering control valve.

TRE0028A

SECTION 41 -- STEERING -- CHAPTER 1

Installation To install the power steering control valve, proceed as follows:

WARNING Always use appropriate tools to align fixing holes. NEVER USE FINGERS OR HANDS.

1. Install the steering motor assembly and secure inside with the four retaining bolts. Tighten bolts to a torque of 44 Nm (33 ft-lbs.). 2. Install the pin at the base of the steering column shaft. 3. Install the two steering motor lower retaining bolts in the gap at the base of the steering column. 4. Install the two steering motor upper retaining bolts between the free gaps of the steering column.

7. Install the control panel and tighten the four retaining bolts. 8. Install the four fittings and the pipes on the steering motor. 9. Install the muffler heat guard and tighten the two retaining screws. 10. Install the muffler and exhaust pipe. 11. Install the four nuts retaining the muffler to the exhaust manifold and the air filter dust ejector pipe with retaining clamp. 12. Install the three rear retaining bolts of the exhaust muffler. 13. Install the right-- and left--hand panels on the control panel. 14. Install the toolbox, with the retaining clamp.

5. Connect the hazard lights switch electrical connections.

15. Install the hood assembly as described in Section 90, and connect the negative cable of the battery.

6. Connect all previously removed electrical connections to the control panel.

16. Close the hood.

SECTION 41 -- STEERING -- CHAPTER 1

Op. 41 204 34 Disassembly To disassemble the hydrostatic steering control valve, proceed as follows:

1. Remove the cover retaining bolts (1).

24701

16 2. Remove the cover (1) by sliding to the side.

24702

17 3. Remove the rotor fixed ring (1), the rotor and the inner spacer.

4. Remove the two O--rings on the rotor fixed ring.

24703

18 5. Extract the rotor drive shaft (1).

24704

SECTION 41 -- STEERING -- CHAPTER 1

6. Extract the thrust washer.

24705

20 7. Remove the threaded plug on the non--return valve seat.

24706

21 8. Extract the O--ring seal from the control valve body.

24707

9. Position the control valve body and the rotor drive shaft so that the sleeve--control shaft trim pin is in a horizontal position. 10. 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

SECTION 41 -- STEERING -- CHAPTER 1

11. Extract the thrust bearing from the rotary valve, complete with the two external rings. Remove the spring retaining ring from the valve seat sleeve.

24710

24 12. Extract the valve--sleeve trim pin.

24711

WARNING On assembly, two reference marks (arrowed) were made on the rotary valve and the sleeve, corresponding to the neural position maintained by the springs. Before removing the springs, check that the marks are clearly visible. If not clear, make new reference marks.

24712

26 13. Extract the rotary valve from the valve seat sleeve.

24713

SECTION 41 -- STEERING -- CHAPTER 1

14. Remove the neutral position springs, extracting them from their seats.

24714

28 15. Remove the dust seal and the O--ring seal from their seats in the control valve body.

20428

29 16. Using a 6 mm Allen wrench, remove the threaded plugs from the two cylinder safety valves and extract the seals.

20429

30 17. Using a 6 mm Allen wrench, remove the setting adjuster screws from the cylinder safety valves. See also fig. 32. 18. Turn the control valve body over and extract the balls, the springs and the spring guides from the two cylinder safety valves.

20432

SECTION 41 -- STEERING -- CHAPTER 1 Cylinder safety valves components (order of disassembly--assembly).

1. Cylinder safety valve ball.

23 4

2. Pressure spring. 3. Setting adjuster screw. 4. Seal. 5. Plug. 25790

32 19. Using a 6 mm Allen wrench, remove the threaded plug on the pressure relief valve and extract the seal.

20434

33 20. Remove the pressure relief valve adjuster screw. 21. Turn the control valve body over and complete disassembly by extracting the spring and the pressure relief valve piston.

20436

34 Pressure relief assembly).

valve

components

(order

1. Pressure relief valve. 2. Pressure spring. 3. Setting adjuster screw. 4. Seal. 5. Plug. 27099

SECTION 41 -- STEERING -- CHAPTER 1

Assembly To assemble the power steering control valve, proceed as follows: 1. Install the rotating valve (1) in the sleeve (2), while aligning the reference marks (indicated by the arrow) made during disassembly.

2 24726

36 2. When available, use tool 380000306 to insert the flat and curved springs (1).

NOTE: Position the springs as shown in the figure.

24728

37 3. Align and center the springs (1) in the seat after installing, (as shown in the figure).

1 24729

38 4. Install the neutral spring retaining ring (1) on the valve seat sleeve (2). The ring must rotate freely without being impeded by the springs.

24730

SECTION 41 -- STEERING -- CHAPTER 1

5. Insert the sleeve trim pin (1).

24731

40 6. Install the thrust bearing (1), in the order shown in Figure 42.

24732

41 1.

Bearing external ring.

Thrust bearing.

Bearing internal ring with bevel facing the shim.

Rotating valve.

Rotating valve seat sleeve.

1 2 3 4 5 24733

42 7. Position the control valve body so that the housing seat on the rotating valve sleeve is positioned horizontally, then insert the bush on guide (1) of tool: 380000305 (for Kin--Ring seal) OR 380000281 (for Rotoglyd seal)

24734

1 43

SECTION 41 -- STEERING -- CHAPTER 1

8. Lubricate the support ring (1), and O-ring ring (2) with hydraulic oil and install on tool (4): 380000305 (for Kin--Ring seals)

OR 380000281 (for Rotoglyd seals)

1 Example of support head for fitting Kin--Ring support and seal rings " (part of tool 380000305)

24735

9. Insert the punch assembly in the previously installed guide bushing (1).

24736

45 10. While holding the external bushing (1), press and rotate the punch (2) to install the O-Ring in the control valve body seat.

24737

1 46

SECTION 41 -- STEERING -- CHAPTER 1 11. Extract tool 380000305 (1), or 380000281 (external bushing and punch). NOTE: The support and seal ring support head remains on the control valve body.

27 1

24738

47 12. Install the thrust bearing and parts removed in operation 29 on the control valve body. Install the sleeve trim pin and hold in a horizontal position to prevent it from slipping out and jamming in the slots inside the control valve body. Install the sleeve (1).

24739

48 13. Press the rotating valve to bring the thrust bearing into contact with the control valve body; this will simultaneously expel the head (1) of tool 380000305 or 380000281 and insert the rings (1) and (2) on the control valve body seat (see figure 44).

24740

1 49

14. Rotate the control valve body and insert the check valve ball (1) into the seat it was removed from.

24741

SECTION 41 -- STEERING -- CHAPTER 1

15. Screw the threaded plug (1) into the check valve seat until the upper surface is below the coupling surface of the control valve body.

24742

51 16. Lubricate the O--ring seal and insert into the seat on the control valve body.

24746

52 17. Fit the thrust washer, so that the holes coincide with the holes in the control valve body.

24747

53 18. Make a reference mark on the upper part of the teeth (1), in line with the seat (2), to indicate the exact position of the valve--to--sleeve trim pin.

24748

SECTION 41 -- STEERING -- CHAPTER 1

19. Fit the rotor drive shaft into the control valve body. Insert tool 380000307 for retaining and centering the rotor drive shaft, between the rotor drive shaft and the thrust washer. Rotate the shaft so as to facilitate coupling between the seat (2) fig. 54 and the trim pin installed in the sleeve.

24749

20. To refit 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 phasing is obtained by aligning the teeth (1), on the trim pin axis plane (shown in fig. 54) with the center line of one of the recesses between the lobes of the rotor.

24750

SECTION 41 -- STEERING -- CHAPTER 1

21. 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 the holes on the thrust washer.

24751

57 22. Install the cover (1), while aligning the retaining holes with the holes on the rotor fixed ring (2).

2 24753

58 23. Remove retaining tool 380000307 and install the special screw and washer in the nonreturn valve seat (1).

24754

59 24. Install the remaining cover retaining bolts (1) with the washers and tighten in diagonal sequence to a torque of 34 Nm (25 ft-lbs.).

24755

SECTION 41 -- STEERING -- CHAPTER 1

25. Turn over the control valve body and insert pressure relief valve piston (1) in the control valve housing.

24756

61 26. Insert the pressure relief valve spring (1).

24757

62 27. Insert the pressure relief valve calibration screw (1).

24758

28. Tighten the plug (2), with the associated seal, using an 8 mm Allen wrench. Tighten to the prescribed torque value 40 -- 60 Nm (29.5025 -44.2537 ft lb), after having carried out the setting on the workbench or on the tractor. 29. Insert the balls (1) into the two cylinder safety valve seats, indicated by the arrows. See fig. 65 component assembly order.

1 2

25789

SECTION 41 -- STEERING -- CHAPTER 1

Cylinder safety valves components (order of assembly) 1. Cylinder safety valve ball. 2. Pressure spring. 3. Setting adjuster screw. 4. Seal. 5. Plug.

25790

65 30. Insert the springs (2, fig. 65) in the cylinder safety valve seats. 31. Using a 6 mm Allen wrench, tighten the two cylinder safety valve setting adjuster bolts (3, fig. 65). NOTE: Setting should be carried out on the workbench or on the tractor to the values shown in the table on page 2.

20475

66 32. Tighten the two plugs (5, fig. 65) and the relative seals (4) using a 6 mm Allen wrench. Once setting is completed, tighten to the prescribed torque value of 30 Nm (22.1269 ft lb).

20429

67 33. When the unit has been assembled, insert the dust seal in the seat in the control valve body.

24764

SECTION 41 -- STEERING -- CHAPTER 1

STEERING CONTROL VALVE TESTING Test conditions. Oil type . . . . . . . . . . . . . . . . . . . IDRAULICAR AP51 Oil viscosity . . . . . . . . . . . . . . . . . . . . . . . SAE 20 W Oil temperature . . . . . . . . . . . . . . . . . 60_C (140_F) Hydraulic pump capacity litres/min (gal/min) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 (3.17) Speed of electric motor . . . . . . . . . . . . . . . rpm 1450

5 4 24912

Installation Diagram of Equipment for Testing the Rotary Valve, Seals and for Setting the Pressure Relief Valve. 4. Restriction 1. Splined control shaft 5. Pressure adjustment handwheel 2. Torque wrench 3. Delivery line A -- CHECKING ROTARY VALVE WEAR 1. Make the connections shown in fig. 68 and complete the circuit as in fig. 69. Using the splined control shaft (1), hold the steering control valve in steering position (right or left). 2. Using the handwheel (5), increase the circuit pressure to as near as possible the pressure relief valve cracking pressure (page 1) without the valve actually opening. 3. Using a torque wrench (2), apply a torque of approx. 34 Nm (2.5 ft-lbs) to the control shaft (1), and check that the rotary valve takes more than 10 seconds to complete one full rotation. If it takes less than 10 seconds, change the rotary valve (4, fig. 2) and the sleeve .

SECTION 41 -- STEERING -- CHAPTER 1

B -- CHECKING RETURN TO NEUTRAL POSITION In the same test conditions as A, check that the valve automatically returns to neutral position when the control shaft (1) is released after each simulated steering movement. C -- CHECKING SEAL EFFICIENCY In the same test conditions as A, hold the valve in steering position with the control shaft (1) for about three minutes and check the seals for leaks. D -- SETTING THE PRESSURE RELIEF VALVE 1. Make the connections as shown in figure (69) and complete the circuit as in figure (70). 2. Using the control shaft (1), simulate a steering cycle (to right or left) so as to interrupt the oil flow to the outlet. 3. Gradually increase the pressure in the circuit by turning the handwheel (5) fig. 69, and check on the pressure gauge that the pressure relief valve (22, fig. 2) cuts in at the pressure shown on page 1. If not, increase or reduce the pressure relief valve setting by tightening or slackening the adjuster screw.

1 7 6

5 3

4 24911

70 1. Splined control shaft -- 2. Plug G 1/2″ -- 3. To throttle -- 4. Outlet -- 5. Three--way coupling G 1/2″ -6. From delivery line -- 7. Outlet coupling G 1/2″ CHECKING THE HYDROSTATIC STEERING PRESSURE RELIEF VALVE WITH STEERING CONTROL VALVE INSTALLED ON TRACTOR. Proceed as follows: 1. Start the engine and run until the oil temperature reaches approx. 50oC (122oF). 2. Switch off the engine and unscrew the oil delivery pipe union (4) on the hydraulic cylinder (5). 3. Install union (2) in place of union (4), and connect the pressure gauge (1) with a 0 -- 150 bar (0 -2175 psi) scale by way of union (3). 4. Start the engine again, bring the speed up to medium rpm, and apply full--steering lock to bring the hydraulic cylinder to the stroke--end position. In this condition, the pressure relief valve (22, fig. 2) should open and the pressure gauge should indicate the value given on page 1. 5. If the pressure gauge reading deviates significantly from the prescribed value, adjust the valve opening pressure by way of the adjuster screw.

3 1

24915

71 1. Pressure gauge (supplied in kit 292870) -- 2. Union 293874 (supplied in kit 292870) to be fitted in place of original union -- 3. Union 291318 (supplied in kit 292870) -- 4. Hydraulic cylinder oil feed pipe -- 5. Hydraulic cylinder.

SECTION 41 -- STEERING -- CHAPTER 1

Steering Pump Components 1. Front cover 2. Cover seals 3. Pump body 4. Gear support 5. Driven and driving gear shafts 6. Gear support 7. Bushing 8. Control side cover 9. Driving shaft seal 10. Spacer

11. Driving shaft seal. 12. Circlip 13. Safety washer 14. Nut 15. Bolt 16. Washer 17. Key 18. Bushing 19. Lockwasher 20. Nut

SECTION 41 -- STEERING -- CHAPTER 1

OP. 41 206 20 HYDROSTATIC STEERING PUMP Disassembly Refer to Figure 72 unless otherwise noted.

WARNING 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 front cover mounting bolt nuts (20) and extract the bolts (15) with washers (16) and (19). Remove cover (1). 2. Remove the driving shaft nut (14) and safety washer (13). 3. Remove the control side cover (8), circlip (12), and seals (9) and (11) with spacer (10). NOTE: Take care so as not to lose the keg (17) or bushings (7) and (18) when disassembling the pump. 4. Mark the pump body (3), gear support (4), gear shafts (5) and support (6) before removing to facilitate reinstallation. Remove these parts and replace if defective. 5. Remove the supports (4) and (6) and gears (5) from the cover (8) and body (3). 6. Remove and discard the seals (2). With parts 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 0.100 to 0.180 mm (0.0039 to 0.0070 in.) The distance (2, fig. 73) must be 0.100 to 0.180 mm (0.0039 to 0.0070 in.) less than the distance (1, fig. 73). 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 seals (2), (9), and (11). 11. Lubricate the parts with clean oil of the same type as used in the steering system. Refer to Section 00.

25227

73 Assembly Refer to Figure 72 unless otherwise noted.

WARNING Always use appropriate tools to align hardware holes. NEVER USE YOUR FINGERS OR HANDS. To assemble the pump carry out the removal operations in reverse order with the following requirements. 1. Ensure maximum cleanliness to prevent foreign matter from entering and damaging the pump; 2. Install the previously marked parts (3), (4), (5), and (6) in original position. 3. Mount the gear supports (4) and (6) in the pump body. 4. Orient the gear supports with the fittings on the external circumference matched with the return pipes and front faces with lubrication millings in contact with gears. 5. Insert the plastic antiextrusion rings on the seals (2). 6. Install seals (9) and (11) with spacer (10) and circlip (12). NOTE: Orient the seals with the cavity between the seal lips on the opposite side of the spacer. Fill the cavity with grease. 7. Fill the pump with hydraulic oil before installing to facilitate priming and prevent cavitation.

SECTION 41 -- STEERING -- CHAPTER 1

STEERING CYLINDER (2WD) Removal

WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. To remove the steering cylinder, proceed as follows: 1. Remove the exhaust pipe, lift the hood and disconnect the negative cable from the battery. 2. Unscrew the unions securing the oil delivery and return hoses (1) to the cylinder (2). 3. Remove the nut securing the cylinder rod end to the steering arm (1).

24768

24858

75 4. Using a suitable puller (1), separate the cylinder rod end from the steering arm.

24859

76 5. Remove the pin securing the steering cylinder (1) to the axle and remove the cylinder. Installation To install the steering cylinder, follow the removal procedure in reverse order.

24860

SECTION 41 -- STEERING -- CHAPTER 1

STEERING CYLINDER (FWD) Removal

WARNING

Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. To remove the steering cylinders, proceed as follows: 1. Disconnect the negative cable from the battery. 2. Unscrew the unions securing the delivery and return hoses to the steering cylinder.

24863

3. Remove the snap ring (1) and remove the cylinder rod articulation pin (2) connected to the stub axle housing.

2 1

24861

79 4. Remove the retaining screw and extract the pin (1) securing the steering cylinder to the axle. Remove the steering cylinder.

NOTE: When removing both steering cylinders and supply pipes, omit step 3 above and carry out steps 2 and 4 for the opposite cylinder.

24862

80 5. Remove the two steer cylinders complete with supply pipes.

24864

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) Chapter 1 -- Axle and Wheels CONTENTS Section

Description

Page

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

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

inverted U--section, telescopic and oscillating at center

Wheel angle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2Â°, corresponding to 15 mm (0 590 ins) (0.590 for 16 in. wheels

Toe--in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (ins)

0 -- 5 (0 -- 0.196)

Diameter of stub axle pin (7, page 4) at bushing . . . . . . . . . . . . . .

mm (ins)

37.961 -- 38.000 (1.494 -- 1.496)

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (ins)

38.050 -- 38.140 (1.498 -- 1.501) (*)

Clearance between stub axle pin and relative bushings . . . . . . . .

mm (ins)

0.050 -- 0.179 (0.001 -- 0.007)

Diameter of axle articulation pin (1, page 4) . . . . . . . . . . . . . . . . . .

mm (ins)

37.961 -- 38.000 (1.494 -- 1.496)

Bore of installed bushings (6) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

mm (ins)

38.050 -- 38.140 (1.498 -- 1.501) (*)

Clearance between stub axle pin and bushing . . . . . . . . . . . . . . . .

mm (ins)

0.050 -- 0.179 (0.001 -- 0.007)

Stub axle articulation

Axle articulation

(*) Value to be obtained without refacing.

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

3 (cont.)

Tires

Standard wheel tracks mm (ins)

7 50 16 in. 7.50--16 in

1500 (59)

7.50--18 7.50 18 in.

1510 (59.5)

Alternative track settings mm (ins) A

1400 (55)

1500 (59)

1600 (63)

1700 (67)

1800 (70.86)

1900 (74.8)

1410 (55.5) (55 5)

1510 (59.5) (59 5)

1610 (63.38) (63 38)

1710 (67.32) (67 32)

1810 (71.25) (71 25)

1910 (75.19) (75 19)

DIAGRAM OF 2WD FRONT WHEEL TRACKS

23928

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

4 1

8 9 10 17 16

20073052

Sections of stub axle, articulation pin and front axle 1. 2. 3. 4. 5. 6. 7. 8. 9.

Axle articulation pin Axle articulation bushing Steering transverse tie rod Stub axle control lever Axle support Bushing Stub axle pin Support ring grub screw (13) Cap

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

Bronze thrust ring Seal Wheel hub Steel thrust washer Grub screw for cap (11) and thrust washer (12) Taper roller bearing for wheel Bearing cover for greasing and adjustment Cylinder fulcrum pin (18) Power steering cylinder installation position

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

TIGHTENING TORQUES

C1 -- 49 Nm (36 ft-lbs)

C2 -- 115 Nm (85 ft-lbs)

C6 -- 186 -- 206 Nm (137 -- 152 ft-lbs)

C5 -- 186 -- 206 Nm (137 -- 152 ft-lbs)

C3 -- (*) C4 -- 186 -- 257.7 Nm (137 -- 190 ft-lbs) 20073053

3 Front axle C1 C2 C3 C4

Axle articulation pin bolt Bolt securing disc to wheel hub Bearing adjuster nut Axle end nut

* See Axle Wheel Hub Installation.

C5 Nut for stub axle pin control lever C6 Nut securing cylinder to fulcrum pin

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

PART

Thread

Front axle Bolt securing axle to engine (5) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Torque setting Nm

ft-lbs

M 18 x 1.5

353

260

Bolt securing axle articulation pin bolt (C1) . . . . . . . . . . . . . . . . . . . . . . .

M 10 x 1.25

Nut for axle end fixing screw . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 16 x 1.5

211

155.5

Nut securing LH and RH levers on the stub axles (4) . . . . . . . . . . . . . .

M 16 x 1.5

294

217

Nut securing ball end for transverse steering tie rod . . . . . . . . . . . . . . .

M 14 x 1.5

118

Nut securing transverse steering tie rod . . . . . . . . . . . . . . . . . . . . . . . . .

M 20 x 1

176

130

Bolt securing front wheel to hub (C2) . . . . . . . . . . . . . . . . . . . . . . . . . . .

M 18 x 1.5

115

SPECIAL TOOLS

WARNING The operations described in this section must be performed only with the ESSENTIAL equipment marked with (X). To operate safely and achieve best results, while saving time and effort, essential equipment must be used in conjunction with the special tools recommended below and tools which you must make yourself and for which you will find the design in this manual.

List of special tools necessary for the various operations described in this section. X 380000541 Adaptor (M12x1.25) for axle articulation pin (use with slide hammer 380000549) 380000237 Wheel lifting hook. 380000549 Slide hammer.

TROUBLESHOOTING Problem Abnormal wear of tires.

Possible cause Incorrect tire pressure.

Incorrect toe-in of front wheels. Poor stability of tractor.

Incorrect tire pressure.

Corrective action Inflate the tires to the correct pressure, referring to the pressures recommended in the Use and Maintenance handbook, and more especially, to the pressures recommended by the manufacturer of the tires fitted. Correct the toe-in. Inflate the tires correctly as detailed above.

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

OVERHAUL FRONT AXLE Removal

DANGER Lift and handle all heavy parts with lifting equipment of suitable capacity. Make certain that the units or parts are supported by appropriate slings and hooks. Ensure that there are no persons in the vicinity of the load to be lifted. To remove the complete axle from the tractor, proceed as follows: 1. Disconnect the negative cable from the battery and isolate it; chock the rear wheels. 2. Lift the front of the tractor.

24765

4 3. Place a stand (1) beneath the engine sump, inserting a block of wood between the engine sump and stand.

1 24766

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

4. Remove the front wheel bolts (1).

24767

6 5. Disconnect the hoses (1) of the power steering cylinder (2).

24768

7 6. Remove the axle articulation pin securing bolt (1).

24769

8 7. Secure the axle by means of a sling (1).

24770

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

8. Take out the axle articulation pin (1) using slide hammer 380000549, equipped with adaptor 380000541 and extension.

24771

10 9. Remove the complete axle (1).

24772

11 Installation 1. To install the complete axle, follow the disassembly procedure in reverse order. Install the axle articulation pin (1) using a bronze punch. 2. Install the bolt connecting the axle articulation pin.

24769

3. Connect the hoses (1) of the power steering cylinder (2).

24768

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

AXLE WHEEL HUB Removal

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. The wheel hubs can be removed with the axle installed on the tractor. Proceed as follows for each wheel. 1. Disconnect the negative cable of the battery and isolate it; chock the rear wheels. 2. Lift the front of the tractor.

24765

14 3. Place a stand (1) beneath the engine sump, inserting a block of wood between the engine sump and stand.

1 24766

15 4. Remove the front wheel bolts.

24767

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

5. Remove the wheel hub bearing cover (1).

24775

17 6. Remove the grease nipple as shown in figure.

TRE4001A

18 7. Remove the split pin (1) securing the wheel hub bearing adjuster nut.

TRE4002A

19 8. Using a socket wrench, unscrew the wheel hub bearing adjuster nut.

24777

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

9. Remove the wheel hub bearing adjuster nut (1).

TRE4003A

21 10. Remove the wheel hub bearing washer (1).

TRE4004A

22 11. Remove the wheel hub (2) and take out the bearings (1 and 3).

24778

23 12. Remove the bearing (1).

TRE4005A

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1 13. Remove black (Twin lip) wheel bearing seal (1).

13 1

TRE4006A

25 14. Remove white back up ring (1).

TRE4007A

26 15. Replace worn bearings and seals, using suitable extractors and punches.

24780

27 Installation 1. Place a hydraulic jack beneath the stub axle and unscrew the bolt (1) fixing the control lever (2) to the stub axle pin.

24782B

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

2. Remove the control lever (1) from the stub axle pin (2).

24783B

29 3. Lower the hydraulic jack and remove the stub axle (1).

24784

1 30

4. Put the stub axle on a suitable vice and install white back up ring (1).

TRE4008A

31 5. Install black (Twin lip) wheel bearing seal (1).

TRE4008A

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

6. Install both black (Twin lip) wheel bearing seal and white back up ring together with a suitable installer and a hammer.

TRE4008A

33 7. Install bearing with a suitable installer and a hammer.

TRE4008A

34 8. The wear sleeve (1) for the seal must be installed in the hub with a high strength bearing fit adhesive compound (loctite) to ensure the secure retention in the hub. The hub and the wear sleeve must be throughly clean and dry. Apply high strength bearing fit compound. Press in the wear sleeve, using a suitable press. After installing the wear sleeve, the compound must be allowed to cure for a minimum of three hours prior to assembling the bearings and seals in the hub.

TRE4008A

35 9. Pack the wheel hub with AMBRA GR9 grease.

10. Refit the wheel hub (2) complete with bearings (1 and 3).

24778

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

11. Install a new nut and, using a torque wrench, tighten the nut to a torque of 196 Nm (265.7407 ft lb), turning the wheel hub (1) simultaneously in order to settle the bearings. 12. Loosen the nut slightly and tighten it again to a torque of 24 -- 29 Nm (32.5397 -- 39.3188 ft lb) while continuing to turn the wheel hub.

Note -- the nut must be changed each time the wheel hub is fitted. 13. Check the rolling torque R, bearing in mind that: R â&#x2030;¤ 5.7864 ft lb

24779

37 14. Install the split pin (1) securing the wheel hub bearing adjuster nut and bend it over the nut to prevent turning the nut.

24776

38 15. Install the grease nipple as shown in figure.

TRE4001A

39 16. Install the wheel hub bearing cover (1).

24775

1 40

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

STUB AXLE Removal

WARNING Handle all parts with great care. Do not put your hands or fingers between one part and another. Wear the recommended safety clothing such as goggles, gloves and safety boots. The stub axles can be removed with the axle installed on the tractor. Proceed as follows for each wheel. 1. Disconnect the negative cable of the battery and isolate it; chock the rear wheels. 2. Lift the front of the tractor.

24765

41 3. Place a stand (1) beneath the engine sump, inserting a block of wood between the engine sump and stand.

1 24766

42 4. Remove the front wheel bolts (1).

24767

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

5. Place a hydraulic jack beneath the stub axle and unscrew the bolt (1) connecting the control lever (2) to the stub axle pin.

24782

44 6. Withdraw the control lever (1) from the stub axle pin (2).

24783

45 7. Lower the hydraulic jack and remove the stub axle (1).

1 24784

46 8. Unscrew the axle end securing bolts (1).

24785

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

9. Remove the axle end (1).

24786

48 10. Clamp the end of the axle in a vice and using a slide hammer, take out the stub axle pin articulation bushing (1).

1 24787

Installation 1. To install the stub axle, follow the disassembly procedure in reverse order, using a suitable hammer to install the new bushings on the axle ends.

24788

50 2. Install the axle end (1).

24786

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

3. At the base of the stub axle install the cap (9, fig. 2), then the levelling rings (1), inserting them on the stop grub screws (8 and 14, as shown in figure 2).

24789

52 4. Install the stub axle on the axle end. 5. Position the control lever (1) on the stub axle pin (2) and tighten the securing screw.

24783

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

ADJUSTMENTS TOE--IN Check the alignment of the front wheels, bearing in mind that for driving in a straight line, the wheels must be at an angle of 2Â° to the vertical. This corresponds to a difference of approximately 15 mm (.59 ins) for 16 in. wheels, between the top edge of the rim (A) and bottom edge (A + X).

A+X

When driving in a straight line, the wheels must be parallel to the longitudinal axis of the tractor or have a maximum of 5 mm (.196 ins) toe--in at the front, measured between the wheel--rims.

To check the toe--in, proceed as follows: 1. Inflate the front tires to a pressure of 2.5 bar (36 psi). 2. Position the steering wheel in the middle of its travel, with one spoke along the longitudinal axis of the tractor. 3. Check that the wheels are parallel with the longitudinal axis of the tractor. 4. With the tractor parked on a flat, level surface, measure the distance (B1) between the front of the wheel rims, at hub height. Make a chalk mark on the rims where the measurement has taken place. Move the tractor forward to rotate both wheels exactly 180Â° and check the measurements again at the chalk marks B2 (now positioned at the rear of the wheels). This will eliminate wheel rim run-out errors. 5. Correct the toe--in, if necessary, by adjustment of the end of the transverse steering tie-rod.

B1 8821

SECTION 44 -- FRONT AXLE AND WHEELS (2WD) -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

SECTION 55 -- ELECTRICAL SYSTEM Chapter 1 -- Instrument Cluster CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

INSTRUMENT CLUSTER DESCRIPTION ANALOG INSTRUMENT PANEL

2 TRE0027A

4 1

The analog instrument panel consists of four display sections: 1) Warning and Indicator Lights; 2) Fuel Level Gauge; 3) Tachometer and Hourmeter; 4) Engine Coolant Temperature Gauge.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

Warning and Indicator Lights 2 10

TRE0621A

2 Condition

Indicator

1. Left direction indicator ON

Flashing (green)

2. Side lights ON

Fixed (green)

3. Main beam headlights ON

Fixed (blue)

4. Water in fuel warning

Fixed (red)

5. Air filter blocked warning

Fixed (amber)

6. Engine oil pressure low warning

Fixed (amber)

7. Battery charge low warning

Fixed (red)

8. Brake fluid level low warning

Fixed (red

9. Hand brake ON

Fixed (red)

10. Right direction indicator ON

Flashing (green)

11. First trailer direction indicator*

Flashing (green)

12. Second trailer direction indicator*

Flashing (green)

13. Power take--off ON

Fixed (amber)

* Not available on North America models.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 1

4 Fuel Level Gauge

This instrument shows the level of fuel in the tank. When the tank is full, the needle moves completely to the right. When the fuel level falls less than 1/4 tank, the needle moves into the red area.

TRE0074A

3 Tachometer and Hourmeter The tachometer portion of this gauge depicts engine speed in rev/min (rpm). The green sector identifies engine speed at which optimum power take-off performance is achieved (respectively 540, 540E and 1000 rev/min). TRE0076A

The hourmeter portion of the gauge signifies the cumulative amount of time that the engine has been operating. The digits on the black background signify hours while digits on the red background (far right) represent tenths of an hour. TRE0076A

Green symbol = power take-off at 540 rev/min.

Blue symbol = power take-off at 540E rev/min.

Yellow symbol = power take-off at 1000 rev/min.

Engine Coolant Temperature Gauge --

Green area = normal temperature.

White area = temperature low.

Red area = engine overheating.

TRE0075A

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

SECTION 55 - ELECTRICAL SYSTEM Chapter 2 - Components CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

ELECTRICAL COMPONENTS DESCRIPTION

INSTRUMENT CONSOLE CONTROLS Lights Control Lever (1) The lever operates the direction indicators, headlights, side lights and the horn.

1 TRE0067A

REAR HOOD CONTROLS Starter Switch

To operate the four functions of the switch, turn the key through the following positions:

A. No power to circuits (key can be removed). Engine stopped: automatic activation of fuel injection cut-off. B. Engine pre-start setting. Operation of panel lights and instruments. Power supplied to various circuits. C. Starting the engine: when released, the key returns automatically to position (B).

TRE0018A

D. Parking lights on, instrument panel lighted (key removable).

1. Starter switch 2. Thermostarter 3. Hazard warning lights switch

4. Cigar lighter 4 1

TRE0018B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

Beacon on/off switch (tractors without cab) (1).

1 TRE0020A

IN-CAB CONTROLS Fender-Mounted Controls

4 2

1. Windscreen Washer

2. Windscreen Wiper 3. Rear Working Lights 4. Front Working Lights 5. Becon Controls (With Cab) 1 TRE0042D

5 5

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

Heating and Air-Conditioning Controls 1. Electric fan speed control

2. Heating control 3. Air-conditioning control

TRE0012B

6 Radio (where applicable)

TRE0077B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2 APPLICABLE COMPONENTS, SENSORS AND SWITCHES Description A. MAIN FUSE BOX (See Figure 8) The tractors fuses and relays are housed under a plastic cover. B. BATTERY (See Figure 8) The tractors are fitted with maintenance-free batteries. Keep the top part clean and dry. Check that the level of electrolyte reaches the top mark and never falls below the lower mark. C. ALTERNATOR (See Figure 8) This provides a square wave signal and recharges the battery. It also provides power required by electric devices. D. TRANSMISSION CLUTCH PEDAL SWITCH (See Figure 8) This switch is activated when the transmission clutch pedal is depressed. E. AIR CLEANER CLOGGED SENSOR (See Figure 9) This is activated when the vacuum in the air operating system exceeds a pre-set value. The warning light illuminates. F. FUEL SEDIMENTER (See Figure 9) Activated when water goes into the fuel filter. G. ENGINE OIL PRESSURE SWITCH (See Figure 9) This is activated as soon as oil pressure in the engine drops less than 0.68 bar. The warning light illuminates. This switch is usually closed. H. FUEL TANK LEVEL SENSOR (See Figure 9) The level of fuel in the tank is detected by way of a sensor. The sensor reading is then displayed by a gauge. I. ENGINE COOLANT TEMPERATURE (See Figure 10) The temperature sensor resistance varies in proportion to the coolant temperature, generating a modulated voltage signal picked up by the gauge. J. BRAKE LIGHT SWITCHES (See Figure 10) These are activated when the brakes are on. K. BRAKE OIL LEVEL SWITCH (See Figure 10) This switch is activated when the fluid level drops below the minimum value and the warning light illuminates. L. PARKING BRAKE SWITCH (See Figure 10) This is activated when the parking brakes are on. M. OPERATOR PRESENCE SWITCH (See Figure 10) A switch in the seat detects when an operator is seated.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

TRANSMITTERS AND SWITCHES

D 26608

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

TRANSMITTERS AND SWITCHES

26608

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 2

TRANSMITTERS AND SWITCHES

L 26608

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 - ELECTRICAL SYSTEM Chapter 3 - Starting System CONTENTS Section

Description

Page

55 201 54

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SPECIFICATIONS Starter motor

BOSCH

Power (kW)

3.5

Maximum current drain without load (Amp)

160 at 11.5 V and 8000 rev/min

Minimum brush length (mm) (in)

7.0 (0.2756)

Minimum switch diameter (mm) (in)

42.5 (1.6732)

Maximum armature shaft end play (mm) (in)

0.4

TIGHTENING TORQUES Nâ&#x2039;&#x2026;m (ft-lb) Starter motor and engine block fastening bolts

34 (25.0771)

Box on starter motor/earth (ground) cable side

16 (11.8010)

Solenoid valve wire nuts

7 (5.1629)

Box nuts on starter motor side

10 (7.3756)

Solenoid valve fastening bolts

5 (3.6878)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

DESCRIPTION AND OPERATION The 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 solenoid, a start-up relay and a clutch pedal switch. These are the basic circuit components used on versions with mechanical gearbox. More sophisticated systems include other components, which ensure the engine can be started only under the proper conditions. There are four types of gearbox: with range reduction gear (synchro command), with range reduction gear and inverter (shuttle command). The starting circuit is illustrated in figure 1. The starter motor is rated at 3.5 kW and has four poles, four brushes with integrated solenoid and positive mesh engagement control. The solenoid consists of two coils connected in parallel. The low resistance pull-in coil is earthed (grounded) via the engine, while the high resistance hold-in coil is earthed (grounded) via the solenoid body. When the ignition switch is closed, with the clutch pedal depressed and gear in neutral (except in the case of mechanical gearboxes), the coils are energized and the plunger is magnetically drawn inside the solenoid. This movement, transmitted by means of an flexible joint mechanism, makes the driving pin-

ion engage the flywheel ring gear. The moment the pinion touches the ring gear, the plunger closes a series of contacts and powers all four field windings directly from the battery, thus giving full power to the starter motor. At this stage, one end of the pull-in coil is connected to the positive battery pole through the starter switch, while the other end in connected to the positive pole through the solenoid valve contacts. The pull-in coil is thus bypassed, without absorbing power, and the hold-in coil alone keeps the plunger in position. The starter motor includes a series of contacts and a two-part solenoid plunger which completely closes the contacts even if the pinion teeth are not perfectly in line with the ring 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 ignition switch is released, power is taken from both the solenoid and the motor. The solenoid return spring, acting on the flexible joint mechanism, frees the driving pinion from the gear and opens the solenoid valve contacts again. A roller type clutch is incorporated to the driving pinion group. This prevents the pinion from overspeeding if it stays engaged with the flywheel ring gear after the engine has been started.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

66062746

1 255a 5b 8-

START-UP CIRCUIT DIAGRAM 11 - Battery 12 - Starter Motor 13 - Alternator 14 - Over Voltage protection devise 18 - Thermostart switch 27 - Fuel shut-off solenoid

Starter switch Fuse box Fuse #13, 15A Fuse #5, 7.5A Starter relay

28 31 35 50 53 61 62 -

Thermostart devise Neutral start switch Maxi Fuse, 40A Clutch pedal switch PTO switch Advance solenoid Solenoid switch

26629

TRE0069A

Fuse Panel

Starter Motor

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

OVERHAUL STARTING SYSTEM TEST ON TRACTOR To easily and quickly trouble-shoot the starting system problems and reach conclusive results, it is recommended that you use a battery/starting tester (high discharge multimeter) with incorporated 0-20V voltmeter and 0-500 A ammeter. When using testing devices, follow test procedures recommended by the manufacturer. If you do not have access to testing devices, carry out the following test using a normal 0-20V voltmeter and a 0-500 Amp ammeter in order to check correct starter motor functioning without removing it from the engine. Before carrying out the test: •

check that the battery is fully charged;

•

check that no wires in the starting system are broken or frayed and that there are no loose connections;

•

check that the engine is not seized.

Power Absorption In Starter Motor Circuit 1. Disconnect earth (ground or negative) cable from battery (3). 2. Disconnect positive battery cable from starter solenoid. Connect the positive ammeter (1) lead to the positive battery terminal clamp and the negative lead to the starter motor solenoid (5) input terminal.

3. Reconnect earth (ground or negative) cable to negative battery terminal clamp (3). 4. Connect the positive voltmeter (2) lead to the positive battery terminal clamp and the negative to the negative battery terminal clamp.

26630

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

5. Disconnect the wire from the injection pump shut-off solenoid. 6. Run the engine and note voltmeter and ammeter readings. Voltage must be constantly about 12V and absorption in the range of 250-300 A. •

If absorption corresponds to the readings above, then the starter motor (4) fig. 4, is working correctly. If voltage drops during the test, follow “Resistance in starting system circuit” procedure (see relative paragraph).

•

If absorption is higher than the readings above, check the circuit as follows. If the starting system circuits are in good condition, then the starter motor is malfunctioning and must be removed for further examination.

•

If absorption is lower than the readings above, the starter motor is malfunctioning and must be removed for further examination.

Resistance In Ignition System Circuit (Voltage Drop) If there is a higher than necessary power absorption, check the circuit to find the cause of the voltage drop occurring within circuit components. IMPORTANT: Disconnect the injection pump solenoid fuel closing wire.

Battery Positive Cable Check 1. Connect the positive voltmeter point (1) to the positive battery terminal clamp (2).

2. Connect the negative voltmeter point to starter motor solenoid terminal (3). 3. Run the engine and check the readings on the voltmeter. If voltage is higher than 0.2 V., check and tighten wire connections. Check voltage again and if it is still high install a new battery cable.

26631

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 Starter Motor Ground Lead Check

7 1

1. Connect the positive voltmeter point (1) to the starter motor casing (2). 2. Connect the negative voltmeter point to the engine block (3). 3. Run the engine and check the readings on the voltmeter. If voltage is higher than 0.2 V., check earth (ground) connections between the starter motor flange and the rear engine cover.

26632

6 Battery Ground Cable Check

1. Connect the positive voltmeter point (1) to the engine block (2).

2. Connect the negative voltmeter point to the negative battery terminal clamp (3). 3. Run the engine and check the readings on the voltmeter. If voltage is higher than 0.2 V., check and tighten the earth (ground) cable connections. Check the voltage again and if it is still higher, then install a new earth (ground) cable.

26633

STARTER MOTOR

Removal

1. Disconnect negative battery cable. 2. Unscrew the nut and bolt (1) and remove the protective cover (2) from starter motor (3).

3. Unscrew the nut and remove power clamp (5) and emergency switch clamp (4).

4. Remove the starter motor securing bolts (6) and remove the starter motor.

4 26634

Installation To install the starter motor, reverse the order of removal.

5 8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

26635

Starter Motor Components 1. 2. 3. 4. 5. 6.

Solenoid Solenoid bolts Bolt and stud group Control side support Lever Reducer

Field windings and casing

Brush holder

Brush plate

10. Armature 11. Clutch

Disassembly Refer to figure 9. 1. Place the starter motor in a vice with protected jaws. 2. Disconnect the biggest braided wire which runs from the field winding casing to the solenoid.

3. Remove the three screws from the front casing and remove the solenoid. Note that the plunger will remain connected to the control lever. 4. Remove solenoid plunger from the control lever by holding and lifting it at the front in order to unclip it from the lever.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3 5. Remove the two nuts from the rear casing and the two screws which fasten the rear cover and brush plate to the casing. Remove clamp C and armature shaft end play spacers, leaving the brush gear on the commutator. Remove the thin metal washer on the commutator side of the armature. 6. At this stage of the procedure, check the brushes and commutator. Check that the brushes are not sticking and, if necessary, clean the brushes and their respective channels with a rag and solvent. Check that the brushes are not worn. If they are worn and minimum length is less than that shown in the technical information table, it will be necessary to change the starter motor. NOTE: The brushes are not serviced separately. They are welded to their support and will not be changed for the whole operating life of the starter motor. 7. Remove the motor casing from the armature and the control side bracket. 8. Remove the control lever knuckle pin from the control side of the casing. 9. Remove the retaining ring which holds the control group and the inner plate from the armature shaft, by first removing the pressure collar perpendicularly from the retaining ring support by means of an appropriately sized tube. Then lever the retaining ring from the groove. 10. Remove armature and control group.

Assembly 1. To assemble the starter motor, reverse the removal procedure. Before reconnecting, test the armature shaft end play and test the starter motor without load.

STARTER MOTOR TESTS AND INSPECTIONS Armature Shaft End-Play 1. Place the starter motor in a vice with protected 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 forward and reset the gauge to zero. Push the armature back as far as it will go and note the gauge reading. 3. Readings must fall within the limits specified in the technical information table. If the value is higher, check that armature and brush plate are not worn. Change the worn components, as necessary, and check end play again.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

Starter Motor Test Without Load (Refer to Figure 10) NOTE: A fully charged battery and a battery/starting tester (high discharge multitester) with carbon battery (variable load resistance) are needed to carry out this test.

7 1

1. Place the starter motor in a vice with protected jaws. 2. Connect negative battery cable (4) to the starter motor flange. 3. Bridge the solenoid contacts (6) with a short wire (7).

4 26636

4. Connect the positive voltmeter point (3) to the positive battery terminal clamp and the negative voltmeter point to the negative battery terminal clamp. Connect the ammeter positive point (1) to the positive battery clamp (4) and the negative point to the battery or to the starter motor terminal clamp. 5. Place a manual tachometer (5) on the end of the armature shaft. Check maximum power absorption. This value is specific for each starter motor and must be included in the range of values in the TECHNICAL INFORMATION table. Regulate carbon battery voltage (2) and armature speed according to the information in the technical information table. 6. If the starter motor does not work according to the technical information specification, check if there are earthed (grounded) field windings, if the armature is scuffed or scraped or if the shaft is misshapen or otherwise damaged. Armature (Refer to Figure 11)

1. The commutator surface must be clean and not burnt. If burning needs to be removed, use fine sandpaper and not abrasive fabric (emery cloth). Finally, clean the commutator with a rag and solvent. 2. If the commutator needs refacing, check it is not smaller than the minimum value specified in the TECHNICAL INFORMATION table. After refacing, the commutator must be polished with sandpaper and cleaned with a rag and solvent. 26637

NOTE: Do not cut the armature metal when making insulation slots.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

3. Armature insulation can be checked by connecting an ohmmeter (1, fig. 12) between commutator segments and armature shaft. This reading should show infinity, in other words there should be no continuity. 4. To test there are no short circuits, use an appropriate testing device. The only alternative is to try changing the armature. 5. If the armature circumference has obviously been in contact with pole pieces, the pole bearings are probably worn. First check to insure that the pole pieces are fixed and that the armature spins well in a lathe. If necessary, change the armature bearing.

Field Windings 1. To test field winding insulation, connect an ohmmeter to each of the coil brushes in turn and to a clean and unpainted area of the casing. There should be no readings, that is, there should be no continuity. 2. To test coil continuity, connect an ohmmeter to each of the coil brushes in turn and to the main power clamp (biggest braided wire). The reading should be 1 â&#x201E;Ś. 3. If there is a failure in the field windings, then it will be necessary to change the whole box and field winding system.

26638

1 12

Bearing Bushings 1. Check if the bushing on the brush plate and in the box on the pinion side are worn. Assemble the armature shaft and note play. Change the bushing if there is too much play. Check the field poles to see if there are any signs of scraping against the casing. This can also be caused by a worn bushing.

Driving Pinion 1. Check the roller clutch operation. The pinion must spin clockwise only. If the pinion is either seized or spins in both directions, or if the pinion teeth are damaged, assemble a new control group. 2. If there is clear evidence of damage to the pinion teeth, check the flywheel ring gear, as described in section 10, Engines.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 3

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SECTION 55 - ELECTRICAL SYSTEM Chapter 4 - Charging System CONTENTS Section

Description

Page

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

SPECIFICATIONS ALTERNATOR CHARACTERISTICS

MODELS TD80D

TD95D

TD95DHC

Neg

15000

Maximum output (A)

Regulator controlled voltage (V)

13.6 - 14.4

Polarity Nominal voltage (V) Max rotation speed (rpm)

Rotor field winding resistance (Ω)

2.9

Stator field winding resistance (Ω)

0.2

New brush length mm (in)

20 (0.787)

Minimum brush length

5 (0.1969)

1.3 - 2.7 (0.29 - 0.60)

540W

mm (in)

Brush spring force N (lb) Maximum power at 2500 erpm

TIGHTENING TORQUES N⋅m

Ft-lb

Alternator fastening bolts

Pulley fastening nut

Rectifier fastening screws

4.0

Brush box and regulator screws

2.7

Terminal nuts

2.7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

DESCRIPTION AND OPERATION The alternator on all models is Bosch 85 A with an external cooling fan. 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 left side of the engine, is operated by a pulley and a V-type driving belt. Alternators contain a built-in regulator.

26639

1 1. 2. 3.

Bosch Alternator Battery Connection (B+ Terminal) Terminal Protection Sheath Alternator Charge Indicator Connection (D+ Terminal)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

1 6 2

26640

Alternator Charging Circuit Diagram 1. 2. 3. 4.

Ignition Switch Alternator Charge Indicator Light Battery Alternator

See figure 2. When the ignition key is turned, a small current passes from the battery through the rotor field winding wiring. The circuit closes powering the charge warning light, the alternator D+ terminal, the rotor field winding, the alternator regulator and ground. At this stage, the warning light comes on and the rotor is partially magnetized. When the engine starts and the rotor, partially magnetized, 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. 6. 7.

Alternator Electronic Voltage Regulation Circuit B+ : Battery Connection 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 increases until it reaches the pre-set regulated voltage level. If the driving belt breaks, there will be no voltage accumulation in the alternator. The charge warning light will stay on, thus indicating a fault.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

4 1

26641

26642

3 Fan Belt on Models Less Air-Conditioning 1. 2. 3. 4.

Alternator Belt Tensioner Belt Tensioner Bolt Fan Belt

Fan Belt on Models With Air-Conditioning 1. 2. 3.

Belt Tensioner Belt Tensioner Bolt Fan Belt

TROUBLESHOOTING PRECAUTIONS

1. CHECKING THE BATTERY

To avoid damaging alternator charging system components, take the following precautions:

Check all battery elements with a densimeter. The battery must be at least 70% charged and efficient.

•

DO NOT MAKE OR INTERRUPT any charging circuit connection, including the battery, while the engine is running.

•

NEVER SHORT-CIRCUIT the alternator positive terminal to check if it is working.

•

ALWAYS DISCONNECT battery cables when recharging the battery in 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 when the alternator is working.

•

CONNECT POSITIVE TO POSITIVE AND NEGATIVE TO NEGATIVE.

PRELIMINARY CHECKS Before carrying out these electrical tests, carefully inspect the charging system and the electrical system in general. Check continuity in all conductors and connections. Check they are all clean and well fastened.

2. CHECKING THE DRIVING BELT Inspect the alternator driving belt and pulley, checking that they are both clean, with no traces of oil or lubricant and in good condition. Check the alternator driving belt tension regularly. If you suspect the belt is not tight, check the tensioner as follows: Belt for versions without air conditioning (Fig. 3) •

loosen the nut (3) which secures the alternator to the tensioner bracket (2).

•

with a lever, move the alternator (1) on the tensioner bracket (2) to reach correct belt tension and tighten the securing nut (3) to 55 N⋅m.

Belt for versions with air conditioning (Fig. 4) •

loosen the belt tensioner securing nuts (3)

•

hold the belt tensioner arm (2) and move it on the bracket to reach the correct belt tension, then tighten the securing nuts (3) to 55 N⋅m.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Correct deflection values, measured by applying the following loads to the middle of the belt:

Load N (lb) Deflection mm (in)

Version without cab or with cab without air conditioning

Version with cab and air conditioning

78 - 98 (17.20 - 21.61)

60 - 75 (13.28 - 16.53)

10 - 11 (0.39 - 0.43)

10 (0.39)

TESTS AND CHECKS These preliminary tests can be carried out without removing any components from the tractor charging circuit. These tests check: •

the alternator wire connections

•

alternator charging current and controlled voltage

•

voltage drop in the alternator charging circuit

•

maximum alternator output

The following testing devices are required: •

0-30V moving coil voltmeter

3. CHECKING THE WARNING LIGHT

•

0-1V millivoltmeter

Turn the ignition key and check the light is completely lit.

•

0-110 A moving coil ammeter

•

1.5 ohm, 110 A varying load resistance

If the warning light does not light completely, check the light bulb. If the light bulb has not blown, carry out the alternator wiring connection tests as described in the paragraph “PRELIMINARY TESTS” in this section. If the light is on, start the engine and run it above minimum speed. The warning light should go out. 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 “ALTERNATOR COMPONENT TESTS” described in this section. If the warning light stays on, check there is no short circuit between D+ wire ending and warning light.

NOTE: Most testing devices on the market today combine several electrical test functions (multimeters). When using these devices, follow the manufacturer’s instructions.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Alternator Wire Connections See figure 5. 1. Disconnect the battery. 2. Disconnect B+ (2) and D+ (3) alternator terminals. 3. Reconnect the battery and turn the ignition key into position ON but without starting the engine. Connect a voltmeter (4) between each terminal and ground (1). There must be voltage at the battery. 26643

If there is no voltage at the battery, check for a continuity fault in the external wiring. See circuit diagram in figure 2. 4. Connect D+ terminal, warning light wire (red) and ground. The warning light should illuminate. 5. Disconnect the battery and reconnect the cables to the alternator at (2) and (3) fig. 5. NOTE: If the warning light does not light up when the wire is connected to the alternator, this means that there is a fault either in the alternator regulator circuit or in the rotor circuit. Check D+ terminal is clean and then test the alternator components as described in this section.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Charging Current and Regulated Voltage See figure 6. 1. Check that all tractor electrical devices are switched off and the ignition key is in the OFF position. 2. Disconnect the negative battery terminal clamp and the B+ negative alternator terminal. 3. Connect an ammeter (1) between the disconnected wire (red) (4) and the B+ alternator terminal (3). 4. Connect a voltmeter (2) between the B+ alternator terminal (3) and ground. 5. Reconnect the battery. Start the engine and run it at 2000 rev/min. Note the readings on the voltmeter and the ammeter. The voltmeter reading should be higher than the battery voltage and when the ammeter reading falls below 10 A, the voltmeter reading should stabilize at 13.6 - 14 V (Magneti Marelli alternator) or 13.6 14.4 V (Bosch alternator). If the voltmeter reading is higher than 14 V or 14.4 V, for Magneti Marelli or Bosch alternators respectively, the alternator regulator must be changed, 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 reads zero amps, then one of the alternator components is malfunctioning. Turn the engine off and carry out the alternator component test, as described in this chapter.

26644

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Charging Circuit Voltage Drop Insulated side voltage drop See figure 7. 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 clamp and 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). 4. Reconnect the negative battery cable and connect a varying load resistance (4) with cursor in minimum current absorption position (maximum resistance) through the battery terminal clamps. 5. Start the engine and increase speed to 2000 rev/min. 6. Decrease resistance charging load (decreasing resistance) slowly until the ammeter reads 45 or 65 A. according to the type of alternator. 7. Note the reading on the millivoltmeter. This must not be higher than 400 millivolts. A reading higher than 400 millivolts indicates malfunctioning due to excessive resistance in the external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 400 millivolts, there is a malfunctioning component in the alternator. Carry out the alternator component tests, as described in this section. 8. Stop the engine.

26645

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Ground side voltage drop test See figure 8. 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 clamp and the alternator casing (negative side of casing). NOTE: Check the varying load resistance (3) is in minimum current absorption position (maximum resistance).

26646

3. Start the engine and increase speed to 2000 rev/min. 4. Increase resistance current load (decreasing resistance itself) slowly until the ammeter (2) reads 85 A. 5. Note the reading on the voltmeter. This must not be higher than 200 millivolts. A reading higher than 200 millivolts indicates malfunctioning due to excessive resistance in the external circuits. If the alternator does not output required power and the millivoltmeter reading is less than 200 millivolts, there is a malfunctioning component in the alternator. Carry out the alternator component tests as described in this section. 6. Stop the engine.

Alternator Maximum Output See figure 9. 1. Check the ignition key is in the OFF position. 2. Disconnect the negative battery cable and the B+ alternator wire (4). 3. Connect an ammeter (5) between B+ alternator terminal (4) and D+ wire (1) (negative side of the wire). 4. Connect a voltmeter (4) between the B+ alternator terminal (5) and ground. 5. Reconnect the negative battery cable. Start the engine and increase speed to 2000 rev/min.

26647

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 6. Increase resistance current load (2) (decreasing resistance) slowly until the ammeter reads 85 A. 7. Note the reading on the voltmeter. This must not be less than 13.6 V. A reading lower than 13.6 V. shows there is a malfunctioning component in the alternator. Carry out the alternator component tests, as described in this section. Alternator Component Tests These alternator tests must be carried out only if the PRELIMINARY TESTS have shown a malfunctioning alternator component. These tests check: •

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 in the tractor. In order to carry out the other alternator tests, it will be necessary to remove the alternator from the tractor. Refer to the section “FUNCTIONAL TESTS” in this chapter.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4 OVERHAUL

ALTERNATOR IMPORTANT: Before disconnecting the alternator wires, check that the ignition key is in the OFF position. Removal 1. Disconnect the negative battery cable. 2. Disconnect B+ (1) and D+ (2) wires from the alternator. 3. Loosen and remove the nut and bolt (3) securing the alternator to the belt tensioner (4).

26648

4. Move the alternator to reduce belt tension (5) and remove it from the alternator pulley (6). 5. Unscrew and remove the nut and bolt (7). Remove the alternator.

26649

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

26650

Alternator Components 1. 2. 3. 4. 5.

Pulley retaining nut Pulley Cooling fan Front support plate Rotor

6. 7. 8. 9. 10.

Stator Rear support plate Rectifier bridge Protection guard Electronic voltage regulator with built-in brushes

Disassembly 1. Firmly fix the alternator horizontally to an appropriate holder with internal surfaces protected with soft material. 2. Remove the guard (1) after unscrewing the nuts which fasten it to the alternator (Fig. 13) 3. Before dismantling the alternator completely, carry out the following tests:

26651

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Alternator Component Testing Rotor and regulator field circuit test The following testing devices are required: •

12 volt battery

•

multitester

•

2 watt test lamp.

See figure 14. 1. Disconnect all alternator wires. 2. Connect a 12 V. battery and a 2.2 watt test lamp (2) in series to D+ (1) and alternator casing (negative side of the casing). 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 these components are satisfactory, then the regulator may be faulty.

26652

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Checking continuity of three stator windings

Ω

Position the points of an ohmmeter (regulated on Ω x1 scale) so that they touch the stator phase ends (a - b - c) in the three possible ways shown in figures 15, 16 and 17. Each reading should show a certain resistance value which should be the same for all three readings. If resistance shows infinity or zero, the measured phase is either interrupted or short-circuited and the stator needs to be changed. 26653

Ω

26654

Ω

26655

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

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 mentioned above (1) (Fig. 18). The second point must be put in contact successively with each of the three terminals (A-B-C): Repeat the three measurements after reversing the instrument points (Fig. 20).

26658

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Positive power diodes test Put 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 reversing the instrument point connections.

26659

21 Negative power diodes test Put an ohmmeter point in contact with the negative (Y) diodes plate and the other successively with each of the three terminals (A-B-C) (Fig. 22). Repeat the three measurements after reversing 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. 22). If there is resistance in both cases, this means short-circuited diodes. Otherwise, with a R=0 value (interrupted diode), change the whole rectifier bridge.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

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. Put both points of an ohmmeter (regulated on â&#x201E;Ś x 1 scale) in contact with the two voltage regulator-brush holder pins. If resistance reading is different from the indicated value or if it shows infinity (interrupted circuit), check and, if necessary, change the rotor (Fig. 23). 26661

23 Op. 55 301 12 Rotor 1. Place a suitable Allen wrench in the hexagonal hole in the alternator shaft to prevent the alternator shaft from turning. With another wrench, unscrew the fan and rotor pulley fastening nut. Draw out the above mentioned parts, spacing collars and alternator washers (Fig. 24).

26662

24 2. Disconnect the excitation diode terminal wire connector (2) from the pin connected to the positive brush. Unscrew and remove the screws (3) securing the electronic voltage regulator (4), complete with brushes, to the rear alternator support. Unscrew nuts (5) and remove the screws fastening the alternator main external parts (Fig. 25).

26663

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Electronic voltage regulator a. Brushes b. Pins

26664

26 Separate the parts (as illustrated) bearing in mind that it is necessary to apply a considerable degree of pressure on the rotor shaft to free the front support plate (6) and the rotor (7) (Fig. 27). If you do not have a press, use a brass drift, to avoid damaging the thread.

26665

27 Unscrew the screws (9) which fasten the rectifier bridge (10) to the rear support plate (8) (Fig. 28). The rectifier bridge must not be dismantled: the spare part is supplied as a complete unit.

26666

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Separate the rectifier bridge (10) from the rear support plate. 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 coil insulation test Put both ohmmeter points (fixed at â&#x201E;Ś x 1 scale) in contact respectively with a slip ring and the rotor casing (see arrows). The instrument should show infinity resistance. If this is not the case, change the rotor (Fig. 31).

26669

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

Check rotor inductor resistance on slip rings Put both ohmmeter points (fixed at â&#x201E;Ś x 1 scale) in contact respectively with the slip rings (see arrows). The instrument should show a certain degree of resistance (Fig. 32). If the instrument reading is different from the prescribed value or shows infinity (interrupted circuit), change the rotor.

26670

32 Check the ball bearing moves freely, without sticking or noise. Check the collectors have not been damaged by the brushes. If this is the case, change the whole rotor. Assembly To assemble, reverse the order of the operations described. Repair 1. Check the rotor and stator poles are not worn. If this is the case, it means the ball bearings are worn, the casings are not in line or the rotor shaft is misshapen.

4 2

NOTE: Alternator ball bearings cannot be serviced separately. When necessary, therefore, both must be changed. 2. Unscrew the screws (1) securing plate (2) that locks bearing (3). Remove it from the front support plate (4) (Fig. 33). Check if it is worn or damaged; if so, change it. Before installing the ball bearing, check the front support plate holder and clean it carefully.

1 3 26671

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 4

3. Installation of bearing (5) on support plate side is different from the one described above. A new rotor complete with bearing must be installed (Fig. 34).

26672

34 Installation 1. Install the alternator by reversing the removal procedure. During installation, remember to: â&#x20AC;˘

Check the negative (ground) battery cable is disconnected from the battery while re-installing the alternator.

â&#x20AC;˘

Adjust the alternator drive belt, as described previously in this chapter.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SECTION 55 - ELECTRICAL SYSTEM Chapter 5 - Battery CONTENTS Section

Description

Page

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Battery Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Relative Density . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dry-Charged Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Normal Charging (Top Up) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Charging Very Flat Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

SPECIFICATIONS CHARACTERISTICS

TYPE OF BATTERY

Voltage (V)

Cold start amperage (C.C.A)

800

Capacity (Ah)

120

Number of elements

Number of plates per element

Energy reserve (SAE) (min.)

210

Weight kg (lb)

35 (77)

Earth (ground) terminal

Negative

TROUBLESHOOTING Discrepancy 1. Internal open circuit. 2. Internal short-circuit. 3. Battery electrolyte leakage. 4. Grid active material separation. 5. Accumulation of sulfate crystals too big to be dispersed. Probable Causes 1. Component failure inside the elements. 2. Excessive crystal growth which can pierce the spacers and cause short circuits. 3. Excessive overload (bad charging system, high voltage fast charging, high operating temperatures). 4. Battery electrolyte freezing. A fully charged battery freezes at -65°C (-85°F). A 50% charged battery freezes between -17°C and -27°C (1.5°F and -16.5°F). A completely flat battery freezes between - 3°C and -11°C (26.5°F and 12°F). Excessively fast charging and boiling caused by gas formation cause the separation of active material from the grids. Separation destroys the battery chemical function.

5. Crystals are formed when batteries are left flat. High temperature and long periods with the battery flat increase this condition. If a battery is left at room temperature for a week it can rarely be charged in the vehicle. Battery recharge requires higher constant voltage. After three weeks the battery will be permanently jeopardized and it will be necessary to follow the procedure described for “very flat batteries”. Fully charged batteries have longer a life. A lead-calcium battery discharges 3% a month. This means that in 16 months it will reach 50% charge. In the tractor, inactive load is approximately 50 mA. To forecast discharge on a vehicle not in use add approximately 8 Ah a week to this value. 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 increases 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 one. If the battery has lasted as forecasted, charge both batteries. If one has stopped before the forecasted time due to a defect, then change only the defective battery.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

DESCRIPTION AND OPERATION The 800cca battery used on TD models is a sealed maintenance-free type. The battery is installed above the front axle support (Fig. 1). NOTE: “Maintenance-free” means that the battery electrolyte, in normal conditions of use, does not leak. It could leak if the battery is loaded over 14.4 V. This, in fact, causes the water to boil due to gas formed as the battery charges up completely. It can be caused by a faulty charging system, by quick charging or topping up. The four main functions of a battery are:

Each element of the battery consists of positive and negative plates, positioned alternatively, one next to the other. Each positive plate is separated from the adjacent negative plate by means of a porous insulating spacer. If one of the positive plates touches a negative plate in the element, the element will shortcircuit and be irreversibly damaged. The positive plates are welded to a collecting bar and form a positive terminal. The negative plates are welded to a similar collecting bar and form a negative terminal. Each positive plate consists of a lead grid with lead peroxide pasted to the grid holes. The negative plates consist of a lead grid with lead sponge pasted to the grid holes.

•

to supply a source of electricity for starting, ignition and instrument lighting and functioning.

•

to control voltage in the electrical system.

The plates are covered by an electrolyte which consists of diluted sulfuric acid solution.

•

to supply electricity when the power required is higher than that produced by the alternator.

The battery casing is made of polypropylene.

•

to support inactive loads from radio and microprocessor memory.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

OVERHAUL BATTERY Op. 55 301 40 Removal 1. Lift the engine hood. 2. Disconnect ground cable from tractor structure and position it safely, away from the structure itself. 3. Loosen the bolts on both terminal clamps and disconnect the positive and negative battery cables. Ensure they do not touch the battery itself. 4. Lift the battery from the tractor by the two handles at each end of the battery. Installation To install the battery, reverse the removal procedure, with the following precautions: •

Check that the battery is clean, there are no signs of electrolyte leak and the breather covers are completely installed. Coat the terminals and clamps with a petroleum jelly (such as Vaseline). Do not use traditional lubricants as they can lead to electrolytic corrosion.

•

Check the battery compartment or support. The clamps should be clean and there should be no stones or other small objects, which could pierce the battery casing.

•

Check that terminal polarity is correct. Check terminal clamp connections are not too tight.

•

If a radio is installed, it will lose all saved data and will need to be reprogrammed. Electronic panels and microprocessors, for those models to which they are fitted, will not lose their memory function.

24569

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 BATTERY MAINTENANCE

Table 1

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, at 25°C (77°F), is at least 1.280.

Temperature °C °F

Alternatively, approximate charge can be measured using a digital voltmeter (± 0.01 V) as follows: less than less than less than more than

10.5 V unusable battery* 11.8 V flat battery 12.3 V half-charged battery 12.6 V fully-charged battery

* See notes to paragraph “TESTS” for instructions on how to recuperate a slightly sulfurized battery. Battery voltage must be registered on a flat battery considering the following: A) the battery must be flat for at least 4 hours

Fully Charged Battery Performance

25.0

77.0

100%

--4.5

24.0

82%

--24.0

--11.0

64%

--27.5

--17.5

58%

--31.0

--24.0

50%

--34.5

--30.0

40%

--37.5

--35.5

33%

Maximum battery life can be obtained by paying the right attention and by carrying out regular checks. The energy capacity output must not be exceeded by constant overload and charging requirements must be respected. Precautions

B) if the vehicle has been used recently, or if the battery has been charged recently, switch the headlights on for 2 minutes.

IMPORTANT: Batteries contain sulfuric acid and generate a highly explosive hydrogen and oxygen mix during charging.

When a battery is flat, the sulfuric acid in the electrolyte combines chemically with the plates and this decreases the relative density of the solution.

•

Do not use devices producing flames or sparks to inspect the electrolyte level.

•

Do not remove battery caps without protecting your hands and your eyes.

A battery densimeter will determine the relative density of the electrolyte in an element. A reduction in the amount of sulfuric acid in the solution will show the degree of charge of that element. The lower the temperature at which the battery operates, the more necessary it is to keep the battery fully charged. For example, a battery with a relative density of 1.225 at 27°C (80°F) can start the engine at mild outside temperatures but might not do so at lower temperatures because of lower battery performance. Table 1 shows the effect of temperature on battery performance.

During battery maintenance, follow the steps below: 1. Keep the electrolyte level 17 mm over the plates. If this is not respected, the acid concentration will vary, which could damage spacers and cause a deterioration in plate performance. 2. Use distilled or de-mineralized water only. Never use tap water or rain water or water from any other source. 3. Keep the battery charged at least 75% to avoid plate sulfurization, performance loss and possible freezing at low temperatures. 4. Avoid overcharging the battery. Excessive charge will generate high internal heat which will cause grid deterioration and water loss. 5. During quick recharge, check the battery temperature does not exceed 50°C. 6. Do not add sulfuric acid to an element unless some electrolyte has been spilt. Before filling, check the solution has the correct relative density. Slow recharge is the only way to recharge the battery completely. You can use a high amperage battery charger to charge the battery with high current intensity for short periods of time. Use a slow charge to bring the battery to its full capacity.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

Dry-Charged Batteries Dry charged batteries must be prepared as followed: 1. Remove the breather caps from each battery element. 2. Fill each element to the recommended level with electrolyte at a relative density of 1.260. NOTE: The electrolyte consists of diluted sulfuric acid, preferably at a temperature of 21° - 32°C (70°F to 89.5°F). 3. After filling, leave the battery to rest for 15 minutes. Check the electrolyte level and top up, if necessary. 4. Charge the battery for 4 hours at 5-8 A., checking that all the elements are producing gas freely. 5. Replace the breather caps.

Charging The Battery Before charging a battery: 1. Clean the battery casing and element covers carefully with ammonia diluted in warm water and clean the terminals; 2. Check the electrolyte level and, if it is below the plate level, top up with distilled water to cover the plates.

Normal Charging (Top Up) 1. Charge the battery completely with a slow battery charger at 3 to 6 amperes for the required time. This can last 36 hours, or more, if the battery is very flat. A severely sulfated battery may not charge. 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, recorded every hour, showing that relative density has stabilized.

2. When using a fast or high ampere charge, follow the manufacturer’s instructions carefully. High charging amperage increases electrolyte temperature and, if the battery charger is not equipped with an automatic time or temperature switch, it can cause the electrolyte temperature to rise above 50°C (122°F). This can cause violent boiling in the battery and damage internal components. 3. Check electrolyte level in each element again and, if necessary, top up with distilled water.

WARNING Explosive gas is formed when a battery is charged. Do not smoke or use naked flames when checking electrolyte level. Check that the battery charger is switched off, before connection and disconnection, to avoid sparks which could ignite the gas. Charging Very Flat Batteries To recharge a Pb-Ca maintenance-free battery we recommend using a constant voltage battery charger. For very flat batteries, charge for 48 hours, at 16 V., with current limitation. This method is self-regulating. High current is provided at the beginning (when the battery voltage is very low). Current decreases progressively when the battery is fully charged (and its voltage is high). If only constant voltage battery chargers are available, we recommend using voltage levels and times shown in table 2. These figures refer to very flat batteries. If the battery is only 50% discharged, use half the time shown (slow charging programme). For other conditions, reduce charging time proportionally. When feasible, use the slowest charging programme for increased battery life.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5 If violent boiling occurs during charging, due to gas formation or electrolyte leakage, or if the battery box is hot (50°C/122°F or higher), temporarily reduce or stop battery charging to avoid damaging the battery. Table 2

Example 1: Temperature below Battery electrolyte temperature Densimeter reading Subtract 11.0 x 0.004 5.5 Correct relative density =

30°C (86°F) 19°C (66°F) 1.270 1.262

120Ah (800 cca) Slow charging programs

30 hrs at 5A 15 hrs at 10A

Fast charging programs (emergency use only)

10 hrs at 18A

Testing Before carrying out battery tests, check the breathers are not blocked, there is no rust, the breather caps are not open and the casing is not cracked. Required testing equipment: •

Example 2: Temperature above Battery electrolyte temperature Densimeter reading Add 10.0 x 0.004 5.5 Correct relative density =

Battery starter tester (high amperage tester)

•

Thermometer

•

Battery charger

Relative density: This test shows the charge level of a battery. 1. With the float in a vertical position, note the reading. 2. Regulate the densimeter reading for battery electrolyte temperature variations subtracting 4 points (relative density 0.004) for every 5.5°C (42°F) below the temperature the densimeter is calibrated at and adding 4 points (relative density 0.004) for every 5.5°C (42°F) above this temperature. The following examples have been calculated with a densimeter calibrated at 30°C (86°F).

1.227

3. Use the following table to determine the charge level.

Densimeter

•

30°C (86°F) 40°C (104°F) 1.220 0.007

Charge condition 100% 75% 50% 25% Flat

Correct Correct relative relative density at density at 15°C (59°F) 25°C (77°F) 1.295 1.253 1.217 1.177 1.137

1.287 1.246 1.210 1.170 1.130

Average battery voltage 12.66 12.45 12.30 12.00 11.84

NOTE: Relative density should not vary more than 0.025 points between cells. 4. If relative density is 1.280 or higher, the battery is fully charged and in good working condition. 5. If the correct relative density is less than 1.280, charge the battery and check the charging system, to find the cause of low battery load. NOTE: If distilled water has recently been added, the battery must be charged for a short period of time to obtain precise densimeter readings. If the battery has been loaded and kept still, the battery electrolyte will be thicker at the base of the elements. The battery must be shaken periodically to mix the electrolyte. This will improve charging amperage and allow more precise densimeter readings during tests.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 5

8 Performance tests

Performance tests help to understand if a battery can adequately run the engine. Voltage readings show battery condition. Before carrying out the test, check the battery 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 nominal battery voltage or slightly higher. Connect the positive tester conductors to the positive battery terminal 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 higher after 15 seconds, the battery has adequate power output and can easily be charged following the normal procedure. If the reading is lower than 9.6 V., battery is not satisfactory for use and the charge must be tested as follows.

4. Set the charging amperage as close as possible to 40 A. 5. After a 3 minute fast charge, read the voltmeter. •

NOTE: A slightly sulfated battery can be renewed using a multiple type battery charger, with upper open circuit voltage limit of 50V. A sulfated 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 some minutes of inactivity, a low charge will show. This is followed by a fast rise in amperage. Amperage must not exceed 14.0 A. and the battery electrolyte temperature must not exceed 50°C. When amperage stabilizes, set the voltage until amperage corresponds to 5 A. Continue this amperage until the relative density of the battery electrolyte stabilizes (1.275 - 1.280 at 20°C (68°F)). This could take approximately 48 hours. Let the battery rest for 24 hours and then carry out the previously described performance test. •

WARNING Do not leave a high discharge tester on the battery for more than 15 seconds.

Test charging: This test is only for those batteries which have not passed the performance test above. 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. 3. Turn the battery charger timer to more than a 3 minute charge and then back to a 3 minute charge.

If the total voltage is higher than 15.5 V., the battery is not satisfactory. It is probably sulfated or worn and must be changed.

If the total voltage is less than 15.5 V., check the relative density of each element and recharge the battery according to the following scale:

Relative density

Fast 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)

NOTE: When there are problems with a battery, check fan belt tension and the complete charging system.

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SECTION 55 - ELECTRICAL SYSTEM Chapter 6 - Electrical Circuits CONTENTS Section

Description

Page

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Diagram Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Electrical Wire Color Coding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Ground Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Fuses and Relays Main Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Fuses and Relay Box (Inside Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 General Diagram - Center (With Cab) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 General Diagram - Center without Cab (ROPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Starter Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Direction Indicator and Hazard Warning Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Windscreen Washer/Wiper Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Brake Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Heating and Air Conditioning Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 ROPS Work Light Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Work Lamp (with Cab) Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Parking/Headlights and Turn Signal Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Connector Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Operator Presence Switch Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Analogue Instrument Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 DESCRIPTION AND OPERATION

ELECTRICAL DIAGRAM SYMBOLS

SYMBOLS THERMOSTARTER SWITCH WATER TEMP. GAUGE SENDING UNIT

HEADLAMPS BRAKE SWITCH HANDBRAKE SWITCH

ENGINE OIL PRESSURE SWITCH STARTER SWITCH FRONT SIGNAL AND PARKING LIGHT

SOLENOID FUEL SEDIMENTER REAR INDICATOR LIGHT

SPEAKER INTERIOR LIGHTS (LAMPS)

BEACON LAMP LIGHTER COMPRESSOR

NUMBER PLATE LAMP SWITCHES GROUND

RELAY WORKLAMPS

REAR WIPER MAIN FUSE STARTER SWITCH

WASHER

HORN

THERMOSTARTER STARTER FUEL LEVEL SENSOR

HEATER ALTERNATOR

DIODE

BATTERY

AIR FILTER RESTRICTION SWITCH

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 ELECTRICAL WIRE COLOR CODING B

Black

Green

Pink

Light green

Tan

Brown

Orange

Purple

Red

Grey

Turquoise

Blue

White

Yellow

GROUND LOCATIONS 1. Instrument cluster ground point 2. Fuse box ground point 3. Cab floor ground point 4. Steering pump pressure sensor ground point 5. Battery ground point 6. Windscreen washer pump ground point 7. 7 pin trailer connector ground point 8. Evaporator top ground point 9. Upper cab ground point 10. Protective diode ground point

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

GROUND LOCATIONS (CONT.) 1

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 GROUND LOCATIONS (CONT.)

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

GROUND LOCATIONS (CONT.) 8

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

FUSES AND RELAYS MAIN BOX

I II III IV

1 PROTECTED CIRCUITS

Fuses

Amps

Main beam headlights

Dipped beam headlights

Front right and rear left side lights

Loader

Engine shut-down solenoid

7.5

Instruments, turn signal switch, horn

Power for can (with can models)

Relays

Hazard warning switch, operators presence module

Beacon lamp, (radio, interior lamps- with cab models)

Turn signal switch

Power for cab (with cab models)

Thermostart

Power socket (with cab models)

Power for cab (with cab models)

Front left and rear right side lights

Brake lights

PTO relay

Starter relay

III

High beam relay

Low beam relay

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

FUSES AND RELAY BOX (INSIDE CAB) FIG- 2 - 3

Fuses and protected circuits are listed below: PROTECTED CIRCUITS

1 2 3 4

ROLE RELAY

7 8

25A 15A 10A 7,5A 20A 15A 7,5A 10A

Fuses

Front wiper

Washer

7.5

Beacon lamp, interior lamps, radio

Heater/Air Conditioning

Rear wiper

7.5

Working lamps switches

Front working lamps

Rear working lamps

TRE0849A

Relays and related circuits are listed below: Relays

TRE0847A

Amps

CIRCUITS

Front work lights

Rear work lights

Power supply

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 GENERAL DIAGRAM - CENTER (WITH CAB)

66072747

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

GENERAL DIAGRAM - CENTER (WITH CAB)

66072748

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 GENERAL DIAGRAM - CENTER (WITH CAB) 1- Instrument panel 1- High beam indicator 2- Cornering lights indicator 3- Left turn signal 4- 2nd trailer indicator 5- 1st trailer indicator 6- Ground 7- Engine coolant temperature signal 8- Not used 9- Not used 10- Fuel level signal 11- Not used 12- Right turn indicator 13- Air filter restriction indicator 14- Not used 15- Engine oil pressure indicator 16- Battery charge lamp 17- Brake low oil level indicator 18- +12V supply 19- Parking brake indicator 20- PTO â&#x20AC;&#x153;ONâ&#x20AC;? indicator 2- Starter switch 3- Multi-function light switch 1- Parking lights 2- Right turn signal 3- Left turn signal 4- High beam 5- Keyed +12V 6- Keyed +12V 7- Low beam 8- Keyed +12V 9- Horn 4- Hazard warning lights indicator sending unit 5- Fuse Box 6- Low beam relay 7- High beam relay 8- Starter relay 9- Compressor 10- Electronic Flasher Unit A1. +12V supply A2. Hazard flasher RH side A3. Trailer lamps RH side A4. Hazard flasher LH side A5. Trailer lamps LH side A6. Hazard switch indicator lamp A7. 2nd trailer indicator lamp A8. Brake low oil level indicator B1. +12V supply B2. Input, LH turn sig. B3. Input, LH turn sig. B4. Input, Hazard flasher switch B5. 1st trailer indicator lamp B6. Left turn sig. output B7. Right turn sign. output B8. Ground

11- Battery 12- Starter 13- Alternator 14- Over voltage circuit breaker (DIODE) 15- Engine oil pressure switch 16- Air cleaner restriction indicator sending unit 17- Water temperature gauge sending unit 18- Thermostarter button 19- Horn 20- Right front parking and turn signal lights 21- Rear left parking,turn signal and stop lights 22- Working lamp 23- Fuel level sensor 24- Beacon lamp 25- Trailer plug 26- Number plate lamp 27- Engine shut off solenoid 28- Thermostarter 29- Hand brake switch 30- Brake stop light switch 31- Starter inhibitor unit 32- Headlamps 33- Worklights switch 34- Rear right parking,turn signal and stop lights 35- Main fuse20 36- Front brake oil unit 37- Rear wiper 38- Cabin fuse box 39- Canin plug 40- Switches 41- Rear work lamps 42- Front work lamps 43- Speaker 44- Interior lamps 45- Wiper 46- Radio 47- Heater 48- Washer 49- Beacon lamp 50- Fuel sedimenter 51- Brake disc 52- Front working lamp relay 53- Rear working lamp relay 54- Front and rear working lamp relay 55- Power relay 56- Front left signal and parking light 57- Front left signal and parking light A-Main and chassis harness connector B-Main and cab harness connector C-Main and headlamp connector D-Main and right front signal connector E-Main and left front signal connector F-Chassis and rear right indicator connector G-Chassis and rear left indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

GENERAL DIAGRAM - CENTER WITHOUT CAB (ROPS)

66062749

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 GENERAL DIAGRAM -CENTER (WITHOUT CAB) 1- Instrument panel 1- High beam 2- Park 3- Left signal 4- 2 nd trailer 5- 1 st trailer 6- Earth 7- Fuel gauge 10- Engine water temperature gauge 12- Right signal 13- Air filter 15- Oil pressure 18- Battery charge indicator 19- Parking brake 2- Starter switch 3- Turn signal switch 4- Hazard warning lights indicator sending unit 5- Fuse Box 6- Low beam relay 7- High beam relay 8- Horn relay 9- Fuel sedimenter 10- Flasher 11- Battery 12- Starter 13- Alternator 14- Over voltage circuit breaker (DIODE) 15- Engine oil pressure switch 16- Air cleaner restriction indicator sending unit

17- Water temperature gauge sending unit 18- Thermostarter button 19- Horn 20- Right front parking and turn signal lights 21- Rear left parking,turn signal and stop lights 22- Working lamp 23- Fuel level sensor 24- Beacon lamp 25- Trailer plug 26- Number plate lamp 27- Engine shut off solenoid 28- Thermostarter 29- Hand brake switch 30- Brake stop light switch 31- Starter inhibitor unit 32- Headlamps 33- Worklights switch 34- Rear right parking,turn signal and stop lights 35- Main fuse 36- Front brake oil unit 37- Brake disc 38- Front left signal and parking light

A- Main and chassis harness connector C- Main and headlamp connector D- Main and right front signal connector E- Main and left front signal connector F- Chassis and rear right indicator connector G-Chassis and rear left indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

STARTER CIRCUIT

66062746

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 STARTER CIRCUIT 1- Instrument panel 2- Starter switch 8- Starter relay 11- Battery 12- Starter 13- Alternator 14- Over voltage circuit breaker 31- Starter inhibitor unit 35- Main fuse 60- PTO A- Main and chassis harness connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview 0,5 G/B --0,5 G/U 0,5 B 0,5 LG/Y 0,5 LG/R 0,5 G/R 0,5 R/W 0,5 U/W

2 6N 6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

0,5 U 0,5 G/W 0,5 B/S -0,5 W/N 0,5 N/Y 0,5 W/B 0,5 G 0,5 R/K --

16N

2,5 W/R

3 N/P

0,5 N/Y

2,5 N/U

2,5 N/R

28 2,5 W/R 2,5 W/Y

2,5 N/R

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

A 1 G/W 1,5 G 1 P/G

0,5 G/B 0,5 R/K 1 G/R 1,5 R 1 R/B 2B 0,5 W/B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT

66062750

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 DIRECTION INDICATOR AND HAZARD WARNING LIGHT CIRCUIT 1- Instrument panel 2- Starter switch 3- Turn signal switch 4- Hazard warning lights indicator sending unit 5- Fuse box 10- Flasher 11- Battery 12- Starter 13- Alternator 20- Front right signal and parking light 21- Rear left, parking, turn signal, stop light 25- Trailer connector 25- Rear signal lamp 34- Rear light parking turn signal and stop light 35- Main fuse 56- Font left signal and parking light 58- Rear right turn signal 59- Rear left turn signal ABDEFG-

Main and chassis harness connector Main and cabin harness connector Main and right front signal connector Main and left connector Chassis and right right indicator connector Chassis and rear left indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

0,5 G/B --0,5 G/U 0,5 B 0,5 LG/Y 0,5 LG/R 0,5 G/R 0,5 R/W 0,5 U/W

2 6N 6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

0,5 U 0,5 G/W 0,5 B/S -0,5 W/N 0,5 N/Y 0,5 W/B 0,5 G 0,5 R/K --

1 G/R 1 G/W

1,5 U 1 S/B 1 P/B 1,5 G/B 1,5 S 1Y 1 TQ 1 W/G 1 W/S 1 TQ/B 1 W/B 1P

1,5 S 1 P/B 1,5 LG/N 1P

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

4 0,5 LG/R

0,5 LG/Y

10 1,5 O 1G 1,5 O

1,5 P

1,5 LG/N

0,5 R/B 1B 1,5 LG/N 1 G/R 1 G/W

1 G/W 16 N

2,5 W/R

21 1 R/B

1,5 B 1 LN/R 1 R/B 1R

1 G/R 1B 1 G/P 1 G/P 1 LN/W --

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

34 1,5 R 1 G/N 1R

1 G/R

1 G/W

1 R/B

1B 1 G/P

1,5 R 1 G/W 1 G/P 1 B

1 R/B 1 G/R 1 G/P 1 B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

A 1 G/W 1,5 G 1 P/G

0,5 G/B 0,5 R/K 1 G/R 1,5 R 1 R/B 2B 0,5 W/B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

WINDSCREEN WASHER/WIPER CIRCUIT

66062751

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 WINDSCREEN WASHER/WIPER CIRCUIT 2- Starter switch 5- Fuse box 11- Battery 12- Starter 13- Alternator 35- Main fuse 37- Rear wiper 38- Cabin fuse box 40- Switches 45- Wiper 48- Washer

55- Power relay B- Main and cabin harness connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

2 16 N 6N

2,5 W/R

6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

1.5 R/LG

1.5 R/G

1 R/W 1 R/W

1.5 W/LG 1.5 U/LG

1R 48--1

1,5 P/G

1 LG/B 48--2

1,5 P/R

1B 1G

1 LG

37 1 LG/B 1 LG

1,5 U/LG 1,5 B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

5 Y/W 1 LG/W

1,5 R

2,5 Y/W

5 Y/W

40 1,5 UL/G 1,5 UL/G 1,5 W/LG

1,5 R/LG 1,5 R/G

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

BRAKE LIGHT CIRCUIT

66062752

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 BRAKE LIGHT CIRCUIT 2- Starter switch 5- Fuse box 11- Battery 12- Starter 13- Alternator 21- Rear left parking, turn signal and stop lights 25- Trailer connector 30- Brake (stop light) switch 34- Rear right parking turn signal and stop light 35- Main fuse

A- Main and chassis harness connector F- Chassis and rear right indicator connector G- Chassis and rear left indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview 0,5 G/B --0,5 G/U 0,5 B 0,5 LG/Y 0,5 LG/R 0,5 G/R 0,5 R/W 0,5 U/W

2 6N 6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

0,5 U 0,5 G/W 0,5 B/S -0,5 W/N 0,5 N/Y 0,5 W/B 0,5 G 0,5 R/K --

16N 2,5 W/R

25 1,5 B 1 LN/R 1 R/B 1R

21 1 R/B 1 RB

1 G/R 1B 1 G/P

1 G/P 1 LN/W --

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

34 30 1,5 R 1 G/N 1,5 G

1,5 G/O

1 G/W 1B 1 G/P

1,5 R 1 G/W 1 G/P 1 B

1 R/B 1 G/R 1 G/P 1 B

3 -

Turn signal switch

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

A 1 G/W 1,5 G 1 P/G

0,5 G/B 0,5 R/K 1 G/R 1,5 R 1 R/B 2B 0,5 W/B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 HEATING AND AIR CONDITIONING CIRCUIT

66062753

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

HEATING AND AIR CONDITIONING CIRCUIT 2- Starter switch 5- Fuse box 9- Compressor 11- Battery 12- Starter 13- Alternator 35- Main fuse 38- Cab fuse box 47- Heater 55- Power relay B- Main and cab harness connector

I- Electrical fans II- Air conditioning - thermostat III- Air conditioning pressure switch IV- Electric fan control switch V- Air conditioning control switch VI- Heating control VII- Air conditioning control switch connection

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

2 16N

2,5 W/R

6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

9 47 1 LG/W

1 LG/W 2,5 B

2,5 G 1,5 G

5 Y/W 1 LG/W

5B 5 Y/W

1,5 R 2,5 Y/W

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

ROPS WORK LIGHT CIRCUIT

66062754

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 WORK LAMP (WITHOUT CAB) CIRCUIT 2- Starter switch 3- Turn signal switch 5- Fuse Box 11- Battery 12- Starter 13- Alternator 22- Work lamp 33- Worklight switch 34- Rear right parking,turn signal and stop lights 35- Main Fuse 57- Work lamp A- Main and chassis harness connector C-Main and headlamp connector F- Chassis and rear right indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

2 16N

6N 6 Y/W

2,5 W/R 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

1 G/N

34 1,5 R 1 G/N 1R

1 G/W 1B 1 G/P

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

1,5 R 1 G/W 1 G/P 1 B

A 1 G/W 1,5 G 1 P/G

0,5 G/B 0,5 R/K 1 G/R 1,5 R 1 R/B 2B 0,5 W/B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

WORK LAMP (WITH CAB) CIRCUIT

66062755

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 WORK LAMP (WITH CAB) CIRCUIT 2- Starter switch 5- Fuse Box 11- Battery 12- Starter 13- Alternator 35- Main Fuse 38- Cab fuse box 40- Switches 41- Rear work lamps 42- Front work lamps 52- Front work lamps relay 53-Rear work lamps relay 54-Front and rear work lamps relay 55-Power relay B-Main and cab harness connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

2 16N

6N 6 Y/W

2,5 W/R 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

40 1 R/W 1 R/W

41 1R

1 G/N 1R

1,5 P/G 1,5 P/R

42 1G 1P

1 LG/B 1 LG

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

B 5 Y/W 1 LG/W

5B 5 Y/W

1,5 R 2,5 Y/W

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

PARKING/HEADLIGHTS AND TURN SIGNAL CIRCUIT

66062756

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 SIDE LIGHTS, MAIN AND DIPPED HEADLIGHTS, PARKING LIGHT CIRCUIT 1- Instrument panel 2- Starter switch 3- Turn signal switch 4- Hazard warning lights indicator sending unit 5- Fuse Box 6- Low Beam Relay 7- High beam relay 11- Battery 12- Starter 13- Alternator 21- Rear left parking,turn signal and stop lights 25- Trailer plug 26- Number plate lamp 33- Worklight switch 34- Rear right parking,turn signal and stop lights 35- Main Fuse A- Main and chassis harness connector C- Main and headlamp connector F- Chassis and rear right indicator connector G- Chassis and rear left indicator connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

Connector Overview

0,5 G/B --0,5 G/U 0,5 B 0,5 LG/Y 0,5 LG/R 0,5 G/R 0,5 R/W 0,5 U/W

2 6N 6 Y/W 2,5 N/U 1,5 R 2,5 W/Y 1,5 U

0,5 U 0,5 G/W 0,5 B/S -0,5 W/N 0,5 N/Y 0,5 W/B 0,5 G 0,5 R/K --

1 G/R 1 G/W

1,5 U 1 S/B 1 P/B 1,5 G/B 1,5 S 1Y 1 TQ 1 W/G 1 W/S 1 TQ/B 1 W/B 1P

1,5 S 1 P/B 1,5 LG/N 1P

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

16 N

2,5 W/R

1,5 O 1G 1,5 P 0,5 R/B 1B 1,5 LG/N 1 G/R 1 G/W

21 1 R/B 1 G/R 1B 1 G/P

1,5 B

1 LN/R 1 R/B 1R

1U/R

1 G/P 1 LN/W --

1U/W

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

1,5 R 1 G/N

1.5 P

1R 0,5 R 1.5 B

1 G/W 1B 1 G/P

A 1 G/W 1,5 G 1 P/G

0,5 G/B 0,5 R/K 1 G/R 1,5 R 1 R/B 2B 0,5 W/B

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

1,5 R 1 G/W 1 G/P 1 B

1 R/B 1 G/R 1 G/P 1 B

1,5 U/W

2,0 U/W

1,5 B

2,0 B 1,0 P/N 1,5 B

1,5 U/R

1,5 P 2,0 U/R

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

OPERATOR PRESENCE SWITCH CIRCUIT

66062757

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6 OPERATOR PRESENCE SWITCH CIRCUIT 2- Starter switch 5- Fuse Box 11- Battery 12- Starter 29- Hand brake switch 35- Main Fuse 37- PTO connector 40- PTO 41- Seat switch A- Main and chassis harness connector

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

TRE0628A

ANALOGUE INSTRUMENT CIRCUIT 1-

Left turn indicator

Brake oil level low

Cornering lights indicator

10 -

Parking brake

Headlamp main beam

11 -

Right turn indicator

Water in fuel

12 -

1st. trailer turn signal*

Air filter blocked

13 -

2nd. trailer turn signal*

Unused

14 -

Unused

Engine oil pressure

15 -

PTO rotational speed

Battery charger

* Not applicable to North America models

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

0,5 G/B --0,5 G/U 0,5 B 0,5 LG/Y 0,5 LG/R 0,5 G/R 0,5 R/W 0,5 U/W

0,5 U 0,5 G/W 0,5 B/S -0,5 W/N 0,5 N/Y 0,5 W/B 0,5 G 0,5 R/K --

SECTION 55 -- ELECTRICAL SYSTEM -- CHAPTER 6

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS Chapter 1 -- Cab

CONTENTS Section

Description

Page

Overhaul . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Control Levers, Seat, Electrical Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Rear Window, Handle and Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Lock and Exterior Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 LH Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Front Wiper Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Cab Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1 OVERHAUL

CONTROL LEVERS, SEAT, ELECTRICAL CONTROLS Disassembly

1. Disconnect the negative cable from the battery.

TRE0247A

2. Take out the four securing screws (1) and remove the covering of the control panel (2). 3. Disconnect the electrical connector from the cab interior light switches (3) and remove the cover.

1 1

2 2 4. Remove the LH panel retaining screws (1).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

5. Remove the three LH panel retaining screws (1).

1 TRE0146A

4 6. Remove the screws (1) on rear panel

5 7. Remove the LH panel (1).

TRE0145A

6 8. Remove the screws (1) of the RH panel retaining elements. 1

TRE0048A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

9. Remove the screws (1) from the RH fenders.

1 TRE0147A

8 10. Remove the screws (1) from the rear panel

TRE0230A

9 11. Remove the RH panel (1). 1

TRE0145A

10 12. Remove the the hand throttle lever (1). 2265 3

TRE0141A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

13. Remove the retaining nut (1) and take off the steering wheel.

TRE0141A

12 14. Remove the retaining bolts on the control panel and detach the electrical connector. Remove the rev counter and the control panel (1)

2 TRE0026A

13 15. Unscrew the retaining screw (2) on the side of the instrument console (rear hood) (1).

2 TRE0150A

14 16. Remove the retaining screws (1) on top of instrument console (rear hood) (2).

2 1

TRE0149A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

17. Remove the instrument console (rear hood) (1).

TRE0148A

16 18. Remove the screws (1) securing the knobs to the control levers and remove the knobs. 1

19. Unscrew the four screws (1) securing the lever panel.

1 18 20. Unscrew the Fast Raise/Lower switch retaining screws (1). 1

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

21. Remove remove the protective cover and the screws (1) securing the hydraulic control lever support (2) to the platform. 2

1 TRE0154A

20 22. Remove the screws (1) holding the auxiliary control valves in place.

TRE0041A

21 23. Remove the screws securing the parking brake support (1) to the platform. Disconnect the parking brake relay and the control lever from vertical rod.

1 22 24. Unscrew the screws (1) securing the shuttle lever (2).

2 1

TRE0180A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

25. Unscrew the control lever retaining screws (1) and remove the control levers. 1

TRE0179A

24 26. Remove the PTO clutch lever support securing screws (1). Disconnect the PTO control lever from the platform.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

27. Remove the four seat securing screws (1). Remove the seat and the covering beneath it. Assembly 1. Install the PTO clutch lever. 2. Install the transmission control levers. 1

3. Install the Fast Raise/Lower cover, securing it to the RH panel with the three screws. 4. Install the RH side panel, securing it to the cab body with the five screws. 5. Install the rectangular PTO cover, the yellow pushbutton and plastic plug. Secure the cover with the two screws. 6. Install the the Fast Raise/Lower switch , the protective cover and the control levers. 7. Install the instrument panel and plug in the electrical connector. 8. Secure the LH side panel with the screws previously removed. 9. Install the RH side panel and cab light control unit and with the securing screws. Reconnect the electrical connector to the plug on the control panel. 10. Install the driverâ&#x20AC;&#x2122;s seat. 11. Connect the negative cable to the battery.

24838

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

REAR WINDOW, HANDLE AND LOCK Disassembly 1. Disconnect the negative cable from the battery.

2. Remove the handle (2), the seals and the threaded pin (1). 1

2 TRE0151A

27 3. Disconnect the two gas struts at the ball and socket joints (1).

1 3 2 TRE0021A

4. Remove the securing screws (1) fig. 29 from the hinges and take out the cab rear windscreen complete with frame (2) fig. 28. 5. With the cab rear windscreen removed, remove the securing screws and the frame (2) fig. 29. Assembly 1. 2. 3. 4.

Install the complete handle unit. Install the locating pin. Replace the rear window rubber seal. Connect the negative cable to the battery.

24852

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

LOCK AND EXTERIOR HANDLE Disassembly 1. Disconnect the negative cable from the battery.

2. Unscrew the three screws (1) securing the interior lock cover (2). 2

TRE0239A

30 3. Remove two screws (1) securing the interior lock (2). 1 2

24897

31 4. Remove the exterior handle by unscrewing the two retaining screws (1) from the inside. Assembly

1. Install the exterior handle. 2. Install the lock. 3. Connect the negative cable to the battery.

24898

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

LH DOOR Disassembly 1 1. Disconnect the negative cable from the battery.

TRE0247A

2. Remove the door closure (gas strut).

1 TRE0238A

34 3. From inside the cab, unscrew the two top screws (1) securing the door hinge.

TRE0238B

35 4. Remove the door.

Assembly 1. Install the left hand door. 2. Install the left hand pillar seal. 3. Connect the negative cable to the battery.

TRE0001A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

FRONT WIPER MOTOR Disassembly 1 1. Disconnect the negative cable from the battery.

TRE0247A

37 2. Remove the roof securing screws.

TRE0124A

38 3. Remove the cap top cover (1) and disconnect the electrical connection from the front wiper motor.

TRE0152A

39 4. Unscrew the wiper blade retaining screw (1). 1

24917

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

5. Unscrew the small nut (1) securing the wiper motor unit.

24918

41 6. Unscrew the large nut and remove the wiper motor unit (1) from top the cab. 1

Assembly 1. Install the motor unit and secure it with the two nuts 2. Install the wiper blade 3. Connect the electrical connector to the motor 4. Install the cab roof lining and all the parts previously removed. 5. Connect the negative cable to the battery.

TRE0225A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

CAB WINDOWS Removal

WARNING Handle all parts with great caution. Do not insert your hands or fingers between one part and another. Wear the prescribed safety clothing, including glasses, gloves and safety footwear. TA6090018

1. If possible, remove any window support blocks present as they can restrict the action of the cutting wire. 2. From inside the cab use a pair of pliers to push the cutting wire (1) fig.43 through the adhesive (2) between the glass and the frame. 3. Thread the cutting wire (1) fig. 44 into the handle and lock it with the screw (2). 4. Anchor the pointed end of the the tool into the adhesive (see figure A). Keep the wire close to the glass and pull on the handgrip (2) fig. 45. 5. Pull the pointed tool from the adhesive and reposition it further along, as shown at (2). Again, pull on the wire, making long cuts on straight sections and short cuts around corners to avoid breaking the glass. Repeat this operation until the window is completely detached. 6. Use a tool with suction cups to remove the window and place it on a suitable surface to avoid damaging it. 7. Completely remove the adhesive from the window surround, taking care not to damage the surround. 8. Remove the adhesive from the glass using a suitable solvent.

9. Clean the frame, as described in operation 7. NOTE: When replacing a broken window, remove the glass fragments still attached to the cab and use a knife blade to cut the adhesive (1) fig. 46, away from the frame. Take care not to damage the frame.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 1

Installation 1. Make sure that the contact area between the glass and the metal frame in the cab is perfectly clean. 2. Using a clean tissue, apply the activator (VP 04604 GURIT ESSEX) around the edge of the glass, where contact will be made with the metal frame. Allow to dry. 3. Shake the bottle of glass primer (Betaprime 5100 GURIT ESSEX) for 60 seconds. Using the applicator provided (1) fig. 47, apply the primer (2) around the edge of the glass, over the top of the dried activator. Allow to dry thoroughly. 4. Shake the bottle of metal plate primer (Betaprime 5402 GURIT ESSEX) for 60 seconds. Using the applicator provided apply around the metal frame, where contact will be made with the glass. Allow to dry thoroughly. 5. Cut the spout of the adhesive dispenser as shown in fig. 48 to obtain a bead of triangular cross--section. 6. Apply a smooth, continuous bead of polyurethane adhesive (Betaseal 1703 GURIT ESSEX) around the edge of the glass over the previously primed area (the cross--section of this bead must be triangular, with a base width of 10 mm [3.93 ins] and a height of 10 mm [3.93 ins]). NOTE: Make sure that the adhesive bead is continuous, i.e., there are no areas where adhesive is missing, otherwise water may penetrate. 7. Insert the window support blocks, if present. NOTE: Leave the clamps in place for 4 hours until the adhesive has completely polymerised. To promote a good bond, do not move the cab or the tractor during this time. 8. Using a tool with suction cups, position the window in its surround and use suitable clamps to apply a uniform pressure to obtain a 4 mm (.157 ins.) thickness of adhesive and ensure perfect adhesion.

47 60

65 7.0 3.0

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS Chapter 2 -- Air Conditioning System

CONTENTS Section

Description

Page

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Section

Description

Page

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

SAFETY Refrigerant must be handled with extreme care to avoid injury; always wear proper personal protective equipment such as gloves and goggles. Liquid refrigerant can cause freezing of the skin and serious damage to the eyes, even blindness in some cases.

Keep refrigerant containers away from heat sources, as the increase of internal pressure due to heating could cause the container to explode.

In contact with a naked flame or hot metal surfaces the refrigerant may give off a toxic gas. If inhaled this gas can cause serious harm.

To avoid the possibility of accidents take the simple precautions described below.

The operation of emptying the system must be carried out in a well--ventilated area, well away from any naked flames.

During the charging and emptying operations, take the necessary precautions to protect the face and above all the eyes from accidental contact with refrigerant.

In case of accident, proceed as follows:

— if refrigerant has entered the eyes, wash immediately with a few drops of mineral oil, then wash them thoroughly with a solution of boric acid and water (one spoonful of acid in 1/4 cup of water) and seek medical assistance immediately.

— freezing of the skin caused by contact with liquid refrigerant can be treated by gradually warming the injured area with cold water followed by application of a greasy cream. Seek medical assistance. — the air conditioning system contains a mixture of refrigerant and oil under high pressure; under no circumstances loosen pipe fittings/couplings or work on pipes without having first evacuated the system. — for the same reason, never unscrew the compressor oil level plug when the system is charged. — do not heat the refrigerant container. Above 50°C (122°F) the pressure increases very rapidly. — keep the air conditioning system away from heat sources to prevent possible explosion due to the increase of pressure in the system.

When transferring refrigerant from one container to another, only use homologated liquid refrigerant containers equipped with safety valves.

Never fill liquid refrigerant containers over 80% of their maximum capacity.

Do not modify the settings of safety valves and the control devices.

Never connect the recovery/recycling and evacuation/charging stations to electrical power outlets with voltages other tan those specified; do not leave the stations powered on unless they are to be used immediately.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 SPECIFICATIONS SANDEN SD 7H15 Compressor Number of cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Total displacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 (inch3)

155 (9.46)

Maximum speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . rpm

6000

Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . kg (lbs)

6.5 (14.3)

Quantity of lubricating oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . cm3 (oz)

185 (6.25)

Type of lubricating oil (code) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PAG SP 20

Air conditioning system

Gas HRC134a

Quantity of HFC--134a refrigerant . . . . . . . . . . . . . . . . . . . . . . gr (lbs)

1600 (3.53)

System delivery side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

16 -- 24 (232 -- 348)

System suction side pressure . . . . . . . . . . . . . . . . . . . . . . . . bar (psi)

0.5 -- 3 (7 -- 43.5)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi)

25 (362.5)

Pressure switch setting (high pressure) . . . . . . . . . . . . . . . . bar (psi)

2 (29)

Temperature of refrigerant fluid at outlet of compressor . . . . oC (oF)

60 -- 120 (140 -- 248)

Temperature of refrigerant fluid at outlet of condenser . . . . oC (oF)

40 -- 60 (104 -- 140)

Temperature of refrigerant fluid at outlet of evaporator . . . . . oC (oF)

0 -- 15 (32 -- 59)

Maximum capacity of electric centrifugal fan I, II, III speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . m3/min (f3/min)

3.5 -- 8.5 (123 -- 300)

Remember that altitude affects pressure, as shown in the table on the right. To obtain the effective pressure in the system, subtract the corresponding correction value from the pressure gauge reading.

Altitude (m) s.l.m.

Absolute atmospheric pressure (psi)

Correction (psi)

14.63

300

14.13

--0.50

600

13.64

--1.00

900

13.14

--1.49

1200

12.64

--2.00

1500

12.14

--2.50

1800

11.64

--3.00

2100

11.25

--3.39

2400

10.85

--3.82

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

SPECIAL TOOLS

WARNING The operations described in this section cannot be carried out without the ESSENTIAL tools marked (X) in the following list. To work in safety and to obtain the best possible results while saving both time and energy, we recommend that the other specific tools in the list are also used.

List of specific tools for the various operations in this section X 380000558

Evacuation and charging station

X 380000559

Recovery and recycling station

294044

Set of flexible hoses for 380000558 and 380000559

294043

Tool kit for 380000558

294042

Receiver--dryer for 380000559

380000314

Gas leak detector with audible leak indication

380000556

Athermal tape for expansion valve

380000312

Combs for cleaning and straightening the fins on the condenser and evaporator

293825

Oil for pumps of stations 380000558 and 380000559

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 DESCRIPTION OF OPERATION

The function of the air conditioning system is to create and maintain optimum working conditions inside the tractor cab. These conditions are with regard to four main factors: — — — —

temperature; humidity; speed; purity of the air in the cab.

Obviously “ideal” conditions will vary from person to person, and so it is not possible to specify optimum values for the above factors; however, we can specify a range of values within which the majority of people will feel most comfortable. With regards to temperature and humidity, it is possible to define a zone, known as the “comfort zone”, within which the temperature--humidity combination corresponds to pleasant environmental conditions. From the diagram it can be seen that humidity should be within the range of 30% to 70% (below 30% there is excessive dehydration of the mucous tissues of the nose and throat, while above 70% the subject has an uncomfortable sensation of dampness in many areas of the body) whereas temperature can vary between 18 and 28°C (64 and 82°F). The air flow speed must not be so high as to cause discomfort; speeds of 0.07 -- 0.25 m/s are normally acceptable With regards to the purity of the air, there are no precise limits, but it is important to remember that the hu-

Simplified psychrometric diagram 1. 2. 3. 4. 5.

man metabolism alters the composition of the surrounding air, increasing the humidity and the quantity of carbon dioxide, while decreasing the percentage of oxygen, etc.. By drawing in small quantities of fresh air from outside the cab, it is possible to eliminate impurities in the air, particularly important in the case of agricultural tractors, where dust from earth, hay etc. can cause extreme discomfort, by installing dry filters on the external air inlets. Air conditioning systems in tractors and agricultural vehicles in general thus serves to neutralize the heat and humidity generated in the cab by controlling the temperature and humidity of the air in -- or drawn into -- the cab to create comfortable working conditions for the operator. The operating principle of an air conditioner is similar to that of a domestic refrigerator: to cool an environment, heat must be removed by means of a physical process (evaporation of a liquid) which absorbs heat from the surrounding air. The liquid used in this process, known as the refrigerant, is a product with a high refrigeration coefficient, low toxicity, which mixes well with lubricating oil. The various components of the system are connected by suitable pipes which ensure that the pressure of the system is maintained.

Relative humidity %

Sensation of unbearable cold. Sensation of cold. Comfort zone. Sensation of heat. Sensation of unbearable heat.

25372

(68)

(77)

(86)

(95)

(104)

Temp oC (oF)

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

There are five main components of the air conditioning system:

pending on the ambient temperature) which thus changes its state from a vapor to a liquid.

1. 2. 3. 4. 5.

The refrigerant, in liquid state at high pressure, is purified by passing through the receiver--dryer (3) from where it flows to the expansion valve (4), which restricts the flow of refrigerant and thus reduces its pressure.

compressor condenser receiver--dryer expansion valve evaporator

To understand the operating cycle of the system, follow the flow of the refrigerant starting from the compressor (1). The compressor draws in refrigerant in vapor form at a pressure of 0.5 to 3 bar (7.25 to 43.5 psi) and it compresses it to a pressure of 16 to 24 bar (232 to 348 psi).

As it passes through the expansion valve (4), part of the refrigerant is transformed into vapor and the low temperature mixture of vapor and liquid thus formed enters the evaporator (5). Here the electric fan causes a continuous circulation of the cab air over the fins of the evaporator (5), helping the refrigerant to absorb heat from the air and thus change completely from a liquid to vapor.

The refrigerant, heated by compression to hot vapor with a temperature of 60 to 120 °C (140 to 248 °F), enters the condenser coil (2) located forward of the engine radiator.

The evaporation process removes heat from the air passing over the evaporator (5) and thus reduces the temperature inside the cab.

The air flow passing over the condenser fins and tubes produced by the forward movement of the tractor cools the refrigerant.

The flow of air over the cold surface of the evaporator (5) also condenses some of the moisture in the air and therefore reduces the humidity in the cab.

This action cools the refrigerant to the point of condensation between 40 to 60 °C (104 to 140 °F) (de-

On leaving the evaporator (5) at 0 to 15 °C (32 to 59 °F), the low pressure mixture is aspirated by the compressor (1) to repeat the cycle.

25373

2 Simplified system diagram 1. 2. 3.

Compressor. Condenser. Receiver--dryer.

4. 5.

Expansion valve with thermostatic sensor. Evaporator.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

CAB HEATING AND VENTILATION CONTROLS Ventilation

Turn on cab ventilation by operating switch (2) fig. 3 and direct the air flow as required by positioning the front vents (3, fig. 4). The operator may select outside air or inside air by adjusting the rear air recirculation vents (1, fig. 5) which can assume two positions. â&#x20AC;&#x201D; vents closed: air is drawn from outside the cab through the lateral filters. â&#x20AC;&#x201D; vents open: the greater part of the air is drawn from inside the air through the vents.

TRE0024A

Fresh air drawn into the cab from outside is always filtered. With the fan in operation, and the doors, windows and recirculation vents closed, the pressure inside the cab is greater than the external pressure and thus air can only enter the cab through the lateral filters after it has been suitably filtered. NOTE: To increase the pressure inside the cab, select outside air only (air recirculation vents 1, fig. 5 closed).

TRE0011A

4 Fan The fan control switch (1, fig. 6) is powered when the ignition switch (fig. 7) is in position B.

A. Low speed. B. Medium speed. C. High speed.

Air Filter

TRE0025A

DANGER

Remember that the filters of the cab provide no protection against antiparasitic chemicals in general. Therefore complete protection against these products can only be achieved by the adoption of additional specific safety measures for the individual product. This applies to all types of filter, for which the prescriptions for use and maintenance must be followed scrupulously. Even the use of active carbon filters does not exempt the operator from adopting the personal safety precautions recommended for the product in question.

TRE0024A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

HEATING The heating control knob (1, fig. 3) allows the operator to regulate the temperature of the air by increasing or decreasing the circulation of coolant from the engine. The fan control switch (1, fig 6) allows the operator to adjust the quantity of air blown into the cab through the vents (3, fig 4)

Temperature Control Knob (1) â&#x20AC;&#x201D; Turned fully counterclockwise = minimum temperature (circulation of hot water shut off). â&#x20AC;&#x201D; Turned fully clockwise = maximum temperature (circulation of hot water fully open). NOTE: The total capacity of the cooling system (including the cab heating system) is 16 liters (16.9 quarts).

IGNITION SWITCH The ignition switch (1) can assume four different positions:

A. No circuits powered (key can be removed). Engine stop:automatic operation of fuel injection shut--off device.

B C

B. Prerequisite position for engine starting. Turn signals and instruments operational. Various devices powered. TRE0018A

C. Start engine: key returns automatically to position (B) when released.

P. Parking lights on, control panel illuminated, auxiliary lights switch powered (key can be removed).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

C 1 B A

TRE0012A

SWITCHING ON THE AIR CONDITIONING AND TEMPERATURE CONTROL

Air Conditioning and Temperature Control Button Operational when ignition switch is in the starting position. With fan control knob (1, fig 8) in positions A--B or C, turn knob (2, fig 8) to switch on the air conditioning.

Heating Control Knob (fig. 8) Turn the knob (1) fully clockwise for maximum heating. Turn knob (1) fully counterclockwise to shut off the flow of water to the heater and thus switch the heating off.

3--Speed Fan Control Knob Operational when ignition switch is in starting position. A. Low speed . B. Medium speed. C. High speed. NOTE: To pressurize the cab see the chapter Ventilation of this section.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

USE OF THE AIR CONDITIONING SYSTEM

Adjustment

The air conditioning system provides cool, dehumidified air or warm dehumidified air.

To obtain correct cab air conditioning, when the system is in operation keep the recirculation vents open and keep the doors, hatch and rear window closed.

To operate the system proceed as follows. NOTE: The air conditioning system is not operational when the engine is not running as the compressor is driven by the engine. Switching on the Air Conditioning With the engine running, turn knob (2, fig. 8) to start the air conditioning. NOTE: Before switching on the conditioner, always switch on the fan. When the fan control knob is in the “off” position, the air conditioning cannot function. After a few minutes of operation, liquid visible in the sight glass on top of the filter should be clear and free of bubbles. If not, consult a specialist at your dealer.

To lower the temperature and, at the same time, the humidity of the air inside the cab, turn knob (2, fig. 8) counterclockwise until the desired temperature is obtained. NOTE: Before starting the engine, check that the air conditioning knob (2 fig. 8) is in the “off” position. NOTE: When working in very dusty conditions, to increase the pressure inside the cab and prevent dust from entering, it is advisable to close the recirculation vents. If you wish to use the dehumidifying function without lowering the air temperature, turn knob (2, fig. 8) clockwise to obtain the desired temperature. After prolonged operation in hot sunshine, to bring the air inside the cab back to the optimum temperature without the tractor moving, switch on the air conditioner and open the rear window or hatch. This will discharge the hot air. Switching Off the Air Conditioning System Before stopping the engine, always switch off the air conditioner by turning knob (2, fig. 8), then turn the fan control knob (1, fig. 8) to the “off “ position.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

COMPONENTS OF THE AIR CONDITIONING SYSTEM Compressor The compressor serves to pressurize the refrigerant and force it through the system. Axial reciprocating piston type, driven from the engine crankshaft via a vee belt. The operating principle of the compressor is as follows: The swashplate (4), on which pivot the ball ends of the connecting rods of the pistons (2), rests on the cam rotor (5). As the cam rotor rotates it exerts a continuous thrust on the swashplate which cannot rotate as it is held by the fixed gear (3). The angle of the swashplate relative to the axis of rotation causes the pistons to reciprocate in their bores. A reed valve (1) in the cylinder head with seven lobes (one for each piston) controls the inlet and discharge stages of the cylinders. The automatic opening and closing of these valves is obtained by preloading of the reeds. The rotating parts of the compressor are lubricated by special oil, inserted during assembly, some of which circulates through the system mixed with the refrigerant.

25375

9 Sanden SD 7H15 1. 2. 3. 4. 5.

Combined inlet and discharge valve. Piston with seal ring. Drive gear. Swash--plate. Cam rotor.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 Condenser

The condenser, (1), located at the front of the tractor, consists of a number of turns of continuous coil mounted in a series of thin cooling fins to provide a maximum of heat transfer in a minimum amount of space. The condenser receives the hot, high pressure refrigerant vapor from the compressor. The hot vapor passes through the condenser coils and outside air is pushed through the condenser by the engine cooling fan. Heat moves from the hot refrigerant vapor into the cooler outside air flowing across the condenser coils and fins. When the refrigerant vapor reaches the pressure and temperature that will induce a change of state, a large quantity of heat is transferred to the outside air and the refrigerant changes to a high pressure warm liquid. In the condenser the refrigerant is transformed from a vapor to a liquid state. As this occurs by transfer of the heat from the refrigerant to the ambient air, the condenser functions in a similar way to the engine radiator. The condenser consists of a series of tubes through which the refrigerant circulates and a finned block which is pressed onto the tubes to covers them completely in thin aluminium fins to help dissipate heat to the ambient air. The condenser is installed in front of the engine cooling radiator so as to benefit from the air flow caused by forward motion of the tractor.

50040413

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Receiver/Dryer

The warm liquid refrigerant continues onto the receiver/dryer where it is filtered and desiccated, to remove any moisture, before passing through an outlet line to the thermostatic expansion valve. The receiver/dryer, (1), stores the liquid refrigerant to be sure a steady flow to the thermostatic expansion valve is maintained under widely different operating conditions.

50040412

11 The receiver--dryer, installed between the condenser and the expansion valve, performs two basic functions, acting as a filter to remove dirt and moisture from the refrigerant and as a temporary storage container during variable charge stages. Water in the system can cause corrosion and damage to system components. For this reason the filter contains substances to absorb humidity. Solid contaminants, such as sand, metal particles resulting from wear of compressor components, oxides, particles from the pipes, etc., can cause damage to the system and therefore must be removed by suitable filters.

2 3 4 5 25376

Receiver--dryer 1. 2. 3. 4. 5.

Sight glass. Upper screen. Disc. Drying agent. Lower screen.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Thermostatic Expansion Valve Serves to reduce the pressure of the refrigerant as it enters the evaporator so that it can change state and thus remove heat from the surrounding air. The expansion valve performs two basic functions: â&#x20AC;&#x201D; metering: the calibrated orifice (6, fig. 13) in the valve body creates a difference in the pressure of the refrigerant at the inlet (4) (liquid state) and the outlet (7) (mixed liquid/vapor); the calibrated orifice (6) also serves to atomize the refrigerant to facilitate subsequent evaporation; â&#x20AC;&#x201D; modulation: inside the valve body a thermostatic sensor controls the valve aperture so that the right quantity of refrigerant enters the evaporator to ensure complete evaporation. If the thermostatic sensor (2, fig. 13) detects an increase in the cab temperature, the flow of refrigerant is increased. A drop in the temperature or an increase in the compressor capacity (due to an increase in the engine speed) will cause a reduction in the flow of refrigerant into the evaporator. The expansion valve is installed on the evaporator inlet fitting (7), and as the internal refrigerant flow control system is completely automatic. It requires no special maintenance. To perform functional testing, when the system is fully charged, check that the system operating pressures are those indicated on page 3.

NOTE: In case of malfunction, replace the valve.

4 7 6

25389

13 Expansion Valve Block 1. 2. 3. 4. 5. 6. 7.

From evaporator outlet. Thermostatic sensor. To compressor suction inlet. From receiver--dryer. Spring. Calibrated orifice and ball. To evaporator inlet.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Air Conditioner Temperature Cycling Control Switch The air conditioner temperature cycling control switch is mounted on the left hand side of the evaporator housing and close to the expansion valve, figure 14.

60--50--009

Thermostatic Switch (ANTIFROST) The thermostatic switch is a safety device equipped with a sensor (1) which is inserted between the fins of the evaporator (2) where it constantly monitors the temperature.

The bulb of the sensor (1) is filled with a special gas which expands or contracts according to the temperature and thus acts on a membrane connected to a complex mechanism which opens or closes a switch in the electrical circuit of the magnetic clutch to switch the compressor on or off as required.

The thermostatic sensor (1) thus prevents ice from forming on the evaporator and obstructing the flow of air into the cab. For this reason it is very important to insert the sensor (1) between the fins of the evaporator (2) as shown in figure 15.

NOTE: In case of malfunction, replace the entire thermostatic switch.

25377

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 Evaporator The cycle is completed inside the evaporator. The refrigerant leaving the expansion valve is a low temperature, low pressure mixture of vapor and liquid. As it passes through the evaporator it absorbs heat from the ambient air, vaporizes and, having performed its cooling function, is aspirated by the compressor as a vapor. The operation of the evaporator is controlled by the expansion valve which delivers the exact quantity of refrigerant needed to produce the required air conditioning effect. The evaporator performs the opposite function to the condenser, but its basic construction is the same, the only differences being its overall dimensions and the layout of the internal pipes. The evaporator also performs another function: dehumidification of the cab. The air passing over the evaporator contains a certain quantity of moisture, and this must be kept within certain limits for operator comfort. Part of the moisture condenses on the fins evaporator and is thus removed from the air. The centrifugal fan draws the ambient air through the fins of the evaporator (where it is cooled and dehumidified) and into the cab. The housing around the evaporator is equipped with a condensate trap from which the condensate is carried outside the vehicle through discharge tubes.

WARNING Switching on the air conditioning system when the ambient temperature is low can damage the compressor. Only operate the air conditioner when the engine is hot and the temperature inside the cab is at least 20 Â°C (68 Â°F). When disassembling pipes, plug the ends with plastic caps to prevent moisture and dust getting inside. Handle the tube of the thermostatic sensor with great care to avoid damage which could prevent the entire system from operating correctly. When unscrewing pipe fittings and unions, always use two spanners to avoid undue torsion. Do not use engine oil of any type to lubricate the system or the compressor. Do not leave the compressor oil container open. Make sure that the cap is replaced and fully tightened. The oil will absorb moisture, which is harmful to the system. Do not transfer compressor oil from its original container to another. Do not add any substances to the refrigerant or compressor oil. Any additives might contain elements incompatible with the refrigerant and thus alter its characteristics. Check that the thermostatic sensor is correctly inserted between the fins of the evaporator.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Low Pressure Cut-out Switch

The low pressure switch, (1), is in the evaporator outlet line and located in the cab roof next to the evaporator and temperature cycling control switch. The purpose of the switch is to shut off the compressor pump in the event of low pressure in the refrigerant system. Low refrigerant pressure may occur due to a faulty expansion valve, icing up of the expansion valve orifice or refrigerant loss. Low refrigerant pressure may result in damage to the compressor pump.

50040414

The low pressure switch is factory set and cannot be adjusted.

Combined High/Low Pressure Cut--out Switch The combined high/low pressure switch, (1), is located on top of the receiver/dryer. The switch shuts off the compressor pump in the event of a restriction in the high pressure line or excessively low pressure due to lack of refrigerant in the system.

Loss of refrigerant in the system will result in insufficient cooling and lubrication and continuous operation will cause damage to the compressor pump. 5004041 0

17 System Pressure Relief Valve A relief valve is located at the discharge port on the compressor, (1). This allows the system refrigerant to be discharged into the engine bay (atmosphere) instead of in the cab, if the system pressure became such that a hose might fail in the cab and cause injury to the operator. This secondary safety feature will only operate in extreme conditions, for example, if the high pressure cut out switch were to fail, or in the event of an engine fire.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 REFRIGERANT RECOVERY--RECYCLING AND EVACUATION--CHARGING STATIONS

WARNING Never under any circumstances use recovery/ recycling or evacuation/charging stations designed for a different refrigerant than that used in the system, as the different chemical compositions of different types of refrigerant render them incompatible with each other. When connecting the stations to the system service valves, always connect the low pressure blue pipes (11, fig. 16, or 17, fig. 17) to the service valve on the suction side of the compressor (S--Suction), and the high pressure red pipes (12, fig. 16, or 15, fig. 17) to the service valve on the discharge side of the compressor (D--Discharge).

2--way pressure gauge unit, with refrigerant flow indicator and pressure gauges (1 and 2, fig. 20), controlling the pressure in the cylinder and at the inlet. Humidity indicator (15, fig. 20), for checking the decontaminated refrigerant. Low pressure switch for automatic cycling of the compressor. Graduated container for the discharge of recovered contaminated oil. Switch (5) 1--0--2 for recovery and cylinder heating. Indicator lights. 294044 flexible service pipes (11, 12 and 16, fig. 20), with safety cocks.

IMPORTANT: check the seals in the pipe connectors (11, 12, 16, fig. 20), or (15, 17, 24, fig. 21) and replace if faulty. Remember that the pipe fittings fitted with seals are to be hand--tightened only without forcing, otherwise the seal will be damaged.

Recovery capacity: (7.05 oz/min). Power supply:

Recovery and Recycling Station (380000559)

Refer to figure 20 and proceed as follows: Replacement of refrigerant decontamination filter:

(Refer to figure 20) The station is designed for the recovery and recycling of refrigerants used in the cab air conditioning systems. The recovered refrigerant is first separated from the system oil by means of a process of vaporization which takes place in a suitable container. In the filter section, the acidity is neutralized, moisture is absorbed and solid particles are screened out. The decontaminated refrigerant is then stored in the metering cylinder. Technical Characteristics Recovery compressor equipped with oil level indicator, discharge valve and service connection. 294042 anti--acid decontaminating filter (3, fig. 20), with a high moisture absorption capacity. Refrigerant/oil distillation cylinder (4, fig. 20), with heating element, automatic device for return of oil to the recovery station compressor and automatic flow control valve for refrigerant entering the station. Graduated cylinder (19, fig. 20), for recovered refrigerant, 2.2 kg (4.8 lbs) capacity, with heater and a safety valve.

200 grams/minute 220 V (50 Hz).

Maintenance

WARNING Every 12 months or earlier if the humidity indicator (15) turns yellow and stays yellow throughout the recovery/recirculation stage, renew the filter (3). 1. Close all the valves including the yellow service valve (9) installed below the distillation cylinder (4). 2. If refrigerant is present in the circuit set pushbutton (5) to position â&#x20AC;&#x153;1â&#x20AC;? and carry out the refrigerant recovery operation. The compressor will stop automatically when the pressure gauge (2) drops to --0.3 bar (4.3 psi). 3. Remove and replace the contaminated filter (3). 4. Carry out a normal evacuation operation for about 30 minutes using the evacuation /charging system (380000558) proceeding as follows: connect the pipe (17, fig. 21) to the service valve (14, fig. 20), open the cock installed on the pipe itself and cocks (4, 10 and 9, fig. 21). On completion of the evacuation operation, close cocks (4, 10 and 9), the cock on the pipe (17) and disconnect pipe (17).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Refer to figure 20 and proceed as follows: 5. To check for leaks at the connections of the previously replaced filter (3) open the yellow service cock (9) on the distillation cylinder (4). 6. Perform a brief recycling operation on the refrigerant contained in the cylinder (19), proceeding as described in the operations 18 to 21, under “Recycling Recovered Refrigerant” and check with a leak detector for leaks at the connections of the new filter. 7. Record the operation on the appropriate service report card. Refer to figure 14 and proceed as follows for Changing the compressor oil in the recovery/recycling station:

WARNING The oil in the compressor of the recovery/recycling station should be replaced with new oil (293825) every 12 months to maintain the station’s refrigerant treatment capacity and to protect the compressor.

1. Open cock (13), and drain the oil into a container to be disposed of in accordance with local regulations for waste oil disposal. 2. Close cock (13). 3. Remove the caps from the service valves (14) on the side of the compressor and (13) on the sight glass.

8. Record the operation on the appropriate service report card.

Evacuation/Charging Station (380000558) Description (Refer to figure 21) The station is designed for the evacuation and subsequent charging of refrigerant in the cab air conditioning systems. The system must first be evacuated to remove any moisture and impurities. The new refrigerant from the external cylinder is transferred to the graduated cylinder before being pumped into the air conditioning system. Technical characteristics Double--acting, ballasted, rotary vacuum pump (21) in oil bath. Charging cylinder (31) with maximum level indicator and graduated scale for measurement of quantity of refrigerant. 5--way pressure gauge manifold with 2 pressure gauges (5 and 6) and 1 vacuum meter. 294044 flexible service pipes (17, 15 and 24) with safety cocks:

4. Connect the service pipe of the evacuation station (380000558) to valve (14) and connect a pick--up pipe from kit 294043 to valve (13) on the sight glass.

Power supply: 220V (50 Hz).

5. Perform the evacuation operation with the pump in operation. The new oil can be aspirated from an external container by means of the pick--up pipe.

Check level and change oil in pump of evacuation/charging station (periodic check)

Maintenance

Refer to figure 21 and proceed as follows:

6. Once the compressor has been filled with correct quantity of oil (half--way up the sight glass) close valve (13), disconnect the pick--up pipe, and replace the cap on service valve (13). Continue the evacuation for approximately 30 minutes.

Periodically check the level and condition of the oil. Drain off the old oil, if necessary, through plug (18). Old oil must be disposed of in accordance with local regulations.

7. On conclusion, close the cocks, switch off the pump, disconnect the service pipe and replace the cap on service valve (14).

Remove cap (13) and fill the vacuum pump (21) with new oil of the type indicated by the pump manufacturer up to the half--way line on the sight glass (14).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

refrigeration

7. Connect the blue service pipe (11) to the valve on the suction (low pressure) side of the compressor (marked “S”).

Recovery of Refrigerant from the Cab Air Conditioning System Using the Recovery/Recycling Station 380000559

8. Connect the red service pipe (12) to the valve on the discharge (high pressure) side of the compressor (marked “D”).

Note -- the recovery operation can be performed more quickly and completely if the system is previously heated, as heat will cause the refrigerant to evaporate and thus be more easily evacuated from the system.

9. Switch on the cab ventilation fan at maximum speed to assist the transfer of heat between the ambient air and the evaporator coil.

AIR CONDITIONING SYSTEM Dehydration, recharging and check.

Refer to figure 20 and proceed as follows: 1. If possible, operate the air conditioning system for a few minutes with the tractor engine running and the hood down, so that the heat produced is gradually transferred to the various components in the system. This will allow any pockets of very cold fluid in the system to evaporate. 2. Stop the engine.

WARNING The recovery operation must only be performed with the tractor engine stopped. 3. If the charging cylinder (19) already contains refrigerant, check that there is still sufficient free volume to contain all the refrigerant in the system (maximum cylinder capacity is 2 kg [4.4 lbs]); if not, transfer the excess refrigerant to an external cylinder in the manner described in “Transfer of Decontaminated Refrigerant” section. 4. Connect the station’s supply lead to a power outlet. 5. Make sure that all cocks are closed except the service cock (9).

10. Open cock (10) on pipe (12). 11. Slowly open cock (6--LOW) on the pressure gauge manifold. Pressure gauge (2) will indicate the presence and pressure of any refrigerant in the system; if the needle is near the “0”, the system is empty. 12. Set switch (5) to position “1” (RECOVERY) -green indicator light will illuminate. The recovery compressor will now start. During the recovery operation, the refrigerant will pass through the distillation cylinder (where it will separated from the oil) and into the decontamination filter (where it will partially cleaned of impurities) to arrive finally in the graduated cylinder. The compressor will stop automatically when the pressure gauge (2) indicates a pressure of --0.3 bar (4.3 psi). 13. Wait a few minutes to allow any pockets of liquid refrigerant left in the system to evaporate and be evacuated. 14. Check the pressure gauge (2): if the pressure has risen above the previous value of --0.3 bar (4.3 psi), the station will automatically start a second recovery operation. If on the contrary, the pressure has remained near the value obtained during the first recovery operation, this indicates that all the refrigerant has been removed from the system and therefore the operation is complete. NOTE: If after 10 minutes of operation the station has not recovered more than 1 kg (2.2 lbs) of refrigerant, check pressure gauge (1). If the pressure reading is over 10 bar (147 psi), open cock (21) and discharge air, then check that pressure gauge (1) does not exceed a maximum of 10 bar (147 psi) throughout the entire recovery operation.

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19 6. Remove the caps from the service valves installed on the suction and discharge lines of the compressor.

15. Close all the cocks except cock (9). Disconnect the service pipes (11 and 12) from the air conditioning system compressor and switch off the station. 16. Switch off the cab ventilation fan.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Recycling Recovered Refrigerant On completion of the recovery operation, the refrigerant, which has already been through an oil separation process, must now be completely decontaminated.

WARNING

At this stage the recovered refrigerant has not yet been completely decontaminated and therefore must not be used in the air conditioning system in this condition. Proceed as follows: 17. All cocks must be closed, with the exception of cock (9, fig. 20) and the station must be switched off -- switch (5) in position “0” and green indicator light off. 18. Connect the end of the yellow service pipe (16) without the cock to the free connector (17) located on the left--hand side of the pressure gauge manifold.

19. Connect the 2 ends of the yellow (16) and blue (11) pipes with connector supplied. 20. Slowly open the cock (18--REF) and the blue cock (6--LOW) on the pressure gauge manifold, and the cocks on the two previously connected service pipes (16 and 11). 21. Set switch (5) to position “1” (RECOVERY) -green indicator light on. The recovery compressor will start to operate and the refrigerant will pass from the graduated cylinder to the recovery circuit (distillation cylinder, filter and compressor) and then return to the graduated cylinder. 22. Continue the operation until the circular sector of the humidity indicator (15) turns green. If after 15 minutes the circular sector of indicator (15) still has not turned green, replace the filter (3) as described previously.

7 8 9

17 25378

10 20

Refrigerant recovery and recycling station 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Cylinder pressure gauge. Recovery control pressure gauge. Anti--acid and decontamination filter. Recovered refrigerant/oil distillation cylinder. Switch. Refrigerant inlet control cock (LOW). Recovered oil discharge cock (yellow). Recovered oil discharge pipe. Oil return to compressor control cock (yellow). Quick--fit connectors. Blue service pipe for connection to suction side of compressor.

12. Red service pipe for connection to discharge side of compressor. 13. Recovered compressor oil discharge cock. 14. Recovery compressor service valve (suction). 15. Humidity indicator. 16. Yellow service pipe for refrigerant transfer. 17. Fitting for refrigerant transfer. 18. Cock (REF) for refrigerant transfer and recycling. 19. Refrigerant cylinder. 20. Safety valve. 21. Cylinder (gaseous stage) discharge cock (yellow).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 NOTE: The circular sector of the humidity indicator (15, fig. 20) must remain green throughout the recycling operation. If the color of the sector tends to vary between yellow and green, or turns completely yellow, this means that the filter is saturated with moisture and therefore must be replaced. Refer to Figure 20 and proceed as follows: 23. On completion of the decontamination operation, close the yellow cock (18--REF) and continue to recover the refrigerant. The compressor will stop automatically when the pressure gauge (2) shows a reading of --0.3 bar (4.3 psi). 24. Close the cock (6--LOW), the two cocks on the ends of the yellow (16) and blue (11) service pipes, disconnect pipes (16 and 11) and switch off the station, turning switch (5) to position “0”. Discharge of Recovered Oil The presence of contaminated recovered oil can be seen in the distillation cylinder (4). The recovered oil must always bee discharged and disposed of according to local regulations. Proceed as follows: 25. Slowly open the yellow cock (7) and discharge the recovered oil in the graduated container. 26. If no refrigerant leaks, whether major or minor, have ever been detected in the system, on recharging, replace the contaminated oil with same quantity of new oil (see page 25). Transfer of Decontaminated Refrigerant from Cylinder (10) to an External Cylinder If for any reason the decontaminated refrigerant is not to be put back into the air conditioning system immediately, for reasons of safety it must be transferred from cylinder (19) to a homologated refillable gas container. Proceed as follows: 27. Check that all the cocks are closed with the exception of cock (9) and that the station is switched off. Check that the container (cylinder) is large enough to contain all the refrigerant to be transferred without exceeding the permitted safety level.

28. Connect the end of the yellow service pipe (16) without the cock to the free connector on the left-hand side of the pressure gauge manifold, and connect the other end (with the cock) to the red connector of the external cylinder. 29. Set switch (5) to position “2” HEATING CYLINDER to switch on the refrigerant heater fitted to the cylinder (19) so as to facilitate the transfer of the refrigerant from the cylinder to the external cylinder. 30. Open the yellow cock (18--REF), the yellow cock on the service pipe and red cock on the external cylinder. 31. On completion of the transfer, close all cocks and switch off the station by turning switch (5) to position 0. Evacuation and Charging the Cab Air Conditioning System Using the Evacuation/Charging Station 38000558 NOTE: Operations 32 to 34, must only be carried out if the graduated cylinder (31) is empty of refrigerant. Evacuation of the Graduated Cylinder (31) of the Evacuation/Charging Station Refer to figure 21 and proceed as follows: 32. Close cocks (4, 22 and 27). 33. Open cocks (3, 9 and 10). 34. Start the pump by turning switch (19) to position “1” to evacuate the cylinder (31). After 5 minutes close cocks (3, 9 and 10) and switch off the pump. Charging the Graduated Cylinder (31) of the Evacuation/Charging Station If the decontaminated refrigerant in the recovery/recycling station is to put back into the tractor air conditioning system immediately, it must be transferred from cylinder (19, fig. 20) to cylinder (31, fig. 21) of the evacuation/charging station, proceeding as follows: 35. With reference to figure 21, connect the end (without cock) of the yellow service pipe (24) to the free connector (28) on the left--hand side of the pressure gauge manifold of the evacuation/ charging station. 36. Connect the other end (with cock) of the service pipe to the free connector (17, fig. 20) on the left-hand side of the pressure gauge manifold of the recovery/recycling station.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 42. Check the quantity of refrigerant in the graduated cylinder (31) fig. 21. 43. From the total quantity of refrigerant required in the air conditioning system indicated in the note following step 48, calculate the quantity of refrigerant that must be added to the cylinder (31) to make up the total amount required. 44. Transfer refrigerant from the external cylinder to the graduated cylinder (31, fig. 21) proceeding as follows. 45. With reference to figure 21, connect the yellow pipe (24) to connector (28) and to the external cylinder containing the refrigerant (upside down if not equipped outlet valve). 46. With reference to figure 21, open the cock on the external cylinder, the cock on the charging pipe (24) and cock (27).

37. With reference to figure 20, check that all the cocks of the recover/recycling station are closed with the exception of cocks (9 and 18) and that on the pipe (16). 38. Check that all the cocks of the evacuation/charging station are closed, with the exception of cock (27, fig. 21). 39. Check that the stations are switched off with switches (5 and 19, fig. 20), in position “0”. 40. With reference to fig. 20, turn switch (5) to position “2” HEATING CYLINDER to switch on the refrigerant heater installed on cylinder (19), to facilitate the transfer of refrigerant to cylinder (31, fig. 21), of the evacuation/charging station. 41. On completion of the refrigerant transfer operation, close all the cocks with the exception of cock (9, fig. 20). Switch off the recovery/recycling station by turning the switch (5) to position “0”.

8 9

25 24

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23 22 21 20 19 18 17

16 21

Evacuation/charging station. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Safety valve. Cylinder pressure gauge. Refrigerant charging cock. Low pressure side cock (LOW). Low pressure gauge. High pressure gauge (red). %--way pressure gauge manifold. Vacuum meter. Vacuum test cock (VAC). Vacuum meter test cock. Vacuum meter safety valve. Oil charging cock. Oil filler cap. Sight glass. Red service pipe for connection to discharge side of compressor. 16. Quick--fit cocks.

17. Blue service pipe for connection to suction side of compressor. 18. Oil drain plug. 19. On/Off switch (I), heater (II). 20. Oil meter connector. 21. Vacuum pump. 22. High pressure side cock (HIGH). 23. Sight glass. 24. Yellow service pipe. 25. Cylinder heater. 26. External ring. 27. Refrigerant transfer cock (REF). 28. Refrigerant transfer connector. 29. Glass rod. 30. Outer casing (Plexiglas). 31. Refrigerant charging cylinder.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 Refer to figure 21 and proceed as follows: 47. Rotate the outer casing (30) so that pressure value indicated on the graduated scale corresponds with the value shown on pressure gauge (2). 48. When the refrigerant in the cylinder has reached the required level, as indicated on the glass rod (29), close the cock of the external cylinder, the cock on the charging pipe (24) and cock (27). NOTE: If excessive time is required to transfer refrigerant from the external cylinder to cylinder (31), slightly open valve (1) and discharge air from the cylinder (31); the pressure reading on gauge (2) should not exceed 5 bar (72.5 psi). Evacuation of the Cab Air Conditioning System (Previously Discharged Using the Recovery/Recycling Station) 49. Remove the caps from the service valves on the suction and discharge lines of the compressor. 50. Connect the blue service pipe (17) to the valve on the low pressure side of the compressor marked “S”. 51. Connect the red service pipe (15) to the valve on the high pressure side of the compressor marked “D”. 52. Open the quick--fit cocks (16). 53. Open cocks (4 -- 9 -- 10 -- 22). 54. Start the pump by turning switch (19) to position “I” and evacuate the system for at least thirty minutes; pressure gauges (5 -- 6 -- 8) should show a negative reading. If the evacuation procedure dose not function correctly, check all connections. 55. Close cock (9), switch off the pump by turning switch (19) to position “0” and check the vacuum seal for at least five minutes using vacuum meter (8). When this is accomplished, close all cocks.

Refer to figure 21 and proceed as follows: 56. Pour the oil into the graduated oil meter of kit 294043. 57. Connect the oil meter to the oil meter (20). 58. Close cocks (4 and 10). 59. Set switch (19) to position “2” to switch on the refrigerant heater on cylinder (31). 60. Open cock (12) and the cock on the graduated oil meter. 61. Check the quantity of oil flowing from the oil meter, and once the required quantity has been reached, close cocks (12) and the cock on the oil meter, then remove the graduated meter. Charging the Cab Air Conditioning System With Refrigerant (After Evacuation) NOTE: The quantity of refrigerant to be put into the system is 1400 grams (3.08 lbs) (refrigerant R134a). Refer to figure 21 and proceed as follows: 62. Keep switch (19) in position 2, with the refrigerant heater in cylinder (31) on, and heat the refrigerant for approximately 10 to 15 minutes to facilitate transfer from the cylinder to the air conditioning system on the tractor. 63. According to the refrigerant type, rotate the outer casing (30) so that the graduated scale and the pressure values correspond with the pressure reading on gauge (2). 64. Move the external ring (26) along the cylinder glass to mark the quantity of refrigerant to be charged. 65. Open cock (22) and charge from the high pressure side. 66. Open cock (3), charge approximately 300 grams (10.5 oz) of refrigerant, close cock (3) and check for leaks.

Charging the Cab Air Conditioning System (After Evacuation) with New Oil

67. If there are no leaks, continue charging up to the prescribed quantity.

If no significant refrigerant leaks have been detected, on recharging, replace the contaminated oil previously recovered in operations (25 and 26) with the same quantity of new oil. If, on the contrary, significant leaks have occurred in the past, proceed with the compressor oil level check procedure described on page 44.

68. On completion of charging, turn switch (19) back to position “0”, close cocks (3 and 22), disconnect pipes (17 and 15), and replace the caps on the service valves. Carry out functional tests with the system set to maximum performance levels, as described below.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

FUNCTION TESTING OF CAB AIR CONDITIONING SYSTEM With the pressure gauges connected to the system in the manner described previously and the cocks closed, proceed as follows: 1. Start the engine and bring it up to a speed of 1500 rpm. 2. Set the cab ventilation fan (1, fig. 8) to the maximum speed. 3. Turn knob (2, fig. 8) to switch on the air conditioning.

25380

22 After about 15 minutes of operation, take the following readings: 4. Pressure on suction side of compressor as indicated by low pressure gauge. 5. Pressure on discharge side of compressor, as indicated on high pressure gauge. 6. Ambient air temperature. 7. Ambient relative humidity. 8. Temperature of air leaving vents inside the cab. The pressure values will depend on the external ambient conditions and the altitude. The system is to be considered as functioning correctly if the pressure readings are within the value ranges indicated on the “Specifications” page, and the temperature readings are within the value ranges indicated within the “Temperature Variation Chart”. 9. Check also the temperature of the low and high pressure sides of the system: — the high pressure side, from the compressor discharge to the expansion valve on the evaporator, should be uniformly hot to the touch; — the low pressure side, from the evaporator outlet to the suction side of the compressor, should be uniformly cold to the touch. There should not be excessive condensation on the suction pipe and the low pressure pipe connector on the compressor.

10. Check that the compressor does not make undue noise. There should be an audible click when the drive is engaged. The sight glass on the receiver--dryer can provide useful information about system operation. The four main possible conditions of the sight glass are shown in figure 22. A. Glass clear: indicates that the system is correctly charged, or that there is no refrigerant in the system ( in the latter case the cooling action of the evaporator would be absent). In some cases, the glass may be clear when the system has been charged with an excessive quantity of refrigerant. In this case it would be necessary to check the pressure readings. B. Bubbles: The formation of vapor or foam bubbles indicates that the system contains an insufficient quantity of refrigerant or the presence of air in the system. Bubbles may also be seen on switching on the system and on disengagement of the electromagnetic clutch. C. Threads of oil: indicates a lack of refrigerant and that the compressor oil is circulating the system. D. Fluid appearance not uniform, streaky: indicates that the drying agent in the filter has escaped, as a result of the containment discs breaking, and is circulating in the system.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

SUMMARY OF THE AIR CONDITIONING SYSTEM CHARGING OPERATIONS (Reference Figure 21) NOTE: The pressure readings reported below are valid for an ambient temperature of 25 °C (77 °F). — Pressure gauge readings on completion of refrigerant recovery and recycling operation.

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— pressure gauge readings with cocks (4 -- 10 -- 22 and 9, fig. 21) open, cylinder (31, fig. 21) with 2000 gr (4.4 lbs) of refrigerant, red and blue service pipes connected to tractor system, cocks (16, fig. 21) closed and compressor off.

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— Pressure gauge readings with cocks (4 -- 10 -- 22 and 9, fig. 21) open, cylinder (31, fig. 21) with 2000 gr (4.4 lbs) of refrigerant, red and blue service pipes connected to tractor system, cocks (16, fig. 21) open and compressor on (initial evacuation stage).

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25384

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

— Pressure gauge readings with cocks (4 -- 10 -- 22, fig. 21) open, cylinder (31) with 2000 gr (4.4 lbs) of refrigerant, red and blue service pipes connected to tractor system, cocks (16) open, compressor off and cock (9) closed (check on vacuum meter that no pressure drops occur over a period of 5 minutes).

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27 — Pressure gauge readings (start of charging -- end of charging). All previously opened cocks are to be closed, with the exception of (4 and 3, fig. 21), compressor off. The level of refrigerant in the charging cylinder can be seen to drop; proceed until only 600 gr (1.3 lbs) of refrigerant remain in the charging cylinder (1400 transferred). The reading of vacuum meter (8) remains the same from the beginning to the end of the charging operation.

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28 Checking the Temperature of the Air Coming Out of the Vents Inside the Cab. If the temperature of the air measured at the vents is within the value range indicated in the table for the external ambient air temperatures specified, the system is functioning efficiently. If the temperature of the air at the vents exceeds the maximum value indicated in the table, refer to the fault diagnosis guide in the following pages.

AIR CONDITIONING SYSTEM OPERATING TEMPERATURE VARIATIONS External ambient temperature Temperature of air at vent outlets (inside cab)

20°C (68°F)

27°C (80.5°F)

4 -- 8°C (39 -- 46°F)

28°C (82°F)

35°C (95°F)

6 -- 12°C (43 -- 53°F)

36°C (96.8°F)

43°C (109.5°F)

12 -- 20°C (53 -- 68°F)

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

CHECKING FOR REFRIGERANT LEAKS USING AN ELECTRONIC LEAK DETECTOR Leak Detector (380000314) The leak detector 380000314 is supplied in its own carrying case which also contains the two power supply batteries, the sensitivity test phial and an ear plug connection for audible leak indication. The instrument consists of a hand--held unit with a flexible probe which houses the sensing tip. To orient the flexible probe, first slacken off the lock ring on the lower left--hand corner of the case.

25387

Mounted on the front of the cases are the sliding on/ off switch, the red indicator led, and the audible leak indicator. Mounted on the rear of the cases is the ear plug connection socket. The battery compartment also houses a sensing tip and a number of spare felt pads. Use Switch the unit ON and start looking for leaks. The frequency and the amplitude of the audible signal will increase if gas is detected.

Maintenance Always make sure that the instrument is switched off before replacing the sensing tip. To remove the tip, unscrew it in a counter--clockwise direction. Fit a new tip and a new felt pad, screwing them in a clockwise direction onto the flexible probe.

In areas affected by gas leaks, switch the instrument on and off. The detector will automatically select a new acoustic level. Perform this test each time the instrument is to be used.

Do not switch on the instrument unless the sensing tip is firmly screwed on to the end of the flexible probe.

Hold the sensing tip near the open phial to test sensitivity. When the instruments starts to emit a signal, switch it on and then off.

On fitting the tip, check that there is no grease or dirt in the connecting hole between the probe and the tip.

Refrigerant Leak Test In this stage the instrument automatically regulates its sensitivity in accordance with the presence of gas in the environment around the sensing tip. The test is performed solely by means of the on/off switch.

In ventilated areas, it can be extremely difficult to trace a large leak due to the rapid dispersion of gas from the source. In this case, place screens around the suspected source to enable more precise localization of the leak. In cases where large leaks obscure the presence of smaller leaks, locate and repair the large leaks first. Proceed to then locate and repair the smaller leaks.

25388

30 Leak detector probe 1. 2. 3. 4.

Flexible probe. Sensing tip. Felt pad. Cover.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

Air Conditioning System

Air Conditioning System Fault Diagnosis Summary

Testing for Leaks with Leak Detector 380000314 and Elimination of Leaks

There are three symptoms of a system malfunction:

With the system charged and the pressure gauges connected, proceed as follows:

— the system does not work at all; — the system does not provide sufficient cooling; — the compressor operates irregularly.

1. Start the engine.

3. Turn knob (2, fig. 8) to switch on the air conditioner.

Bearing in mind that insufficient cooling may also result from causes external to the air conditioning system, generally a mechanical check and visual inspection will provide useful information about the efficiency of the system.

4. Bring the engine up to a speed of approximately 1500 rpm.

This information can then be completed by electrical testing.

2. Set the ventilation fan to maximum speed.

5. Switch on the electronic leak detector. 6. Move the probe around all pipe connections and all possible points of leakage: — The presence of refrigerant, and thus a leak, is signalled by an increase in the frequency of the audible signal. NOTE: Refrigerant is heavier than air, and so it is easier to detect below the leak rather than above it. 7. If leaks are found in the pipe connections, eliminate the leak(s) by tightening the fitting. NOTE: If any of the system components requires replacement, it is always necessary to perform the recovery, recycling and charging operations as previously described.

If at this stage, the problem has still not been identified, it will be necessary to carry out a more detailed search by analyzing the pressure readings in the various parts of the system. Visual Inspection of Components These checks are to be carried out with the engine stopped and with the heating and air conditioning system switched off. — Check the compressor mountings and the relative support, pulley alignment, belt tension. — Look for visible signs of refrigerant leakage (presence of oil on fittings). — Look for visible leaks of liquid refrigerant. — Inspect the condition of the pipes, particularly those in contact with the engine, as well as pipe fittings/connectors and hose clamps. — Check that the evaporator, the heater matrix, and the condenser are clean. Remove foreign matter as required. — Check the condition and position of the thermostatic sensor (fig.15) in the evaporator. — Check that external air intakes are not blocked. — Check the condition of the condensate discharge pipes.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 MAINTENANCE OF THE AIR CONDITIONING SYSTEM

2) CONDENSER: Check mounting, and that the fins are free from excessive deposits. Straighten any bent fins using the special comb 380000312.

At the start of the season in which the system will be used, check that the system is functioning properly and efficiently. If the system has been out of use and charged for a prolonged period, oil may have flowed out of the compressor to other parts of the system. This oil must be returned to the compressor. To do this, start the engine and run it at approximately 1500 rpm for about 10 minutes. Switch on the ventilation fan at maximum speed. Turn control knob (2, fig. 8) to switch on the air conditioning. Check that the relative temperatures of the external ambient air and the air flowing out of the vents inside the cab correspond to the values indicated within the “Temperature Variation Chart”. If so, the system is operating efficiently, and a visual inspection of the main components will be sufficient.

NOTE: Carry out the same checks on the EVAPORATOR (9) and CONDENSER (5, fig. 31). 3) RECEIVER--DRYER: the sight glass on the receiver--dryer can provide useful information regarding system operation. Replace the receiver--dryer after the system has been repaired on two occasions. 4) EXPANSION VALVE: does not require maintenance. In the case of malfunction, check the valve and thermostatic sensor as previously described or consult factory trained personnel. If the temperature of the air at the vent outlets does not conform to the indications given in the “Temperature Variation” chart, proceed with the system fault diagnosis procedure as previously described. NOTE: Should one or more system components require replacement, it will be necessary to carry out the recovery, recycling and charging operations as previously described.

Proceed as follows: 1) COMPRESSOR: Check the mountings, drive belt tension and oil level.

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31 Schematic of the air conditioning system. 1. 2. 3. 4. 5.

Compressor. Suction line (low pressure). Discharge line (high pressure). Hot air. Condenser.

6. 7. 8. 9. 10.

Receiver--dryer. Sight glass. Expansion valve with thermostatic sensor. Evaporator. Cool, dehumidified air.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

TROUBLESHOOTING THE SYSTEM DOES NOT WORK

Check fuses.

Check compressor drive belt tension.

Check if the clutch coil is receiving power.

Check that the earth contact is established.

Check the system control devices -- the relays, wiring, thermostat, etc. Visually check the condition of all fittings, unions and pipes. Check the clearance between the front disc and pulley of the electromagnetic clutch.

6. 7.

25374

Schematic of air conditioning system. 1. 2. 3. 4. 5.

Compressor. Compressor inlet pipe (low pressure). Compressor outlet pipe (high pressure). Hot air. Condenser.

6. 7. 8. 9. 10.

Receiver--dryer. Sight glass. Expansion valve with thermostatic sensor. Evaporator. Cool, dehumidified air.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

TROUBLESHOOTING (cont.) INSUFFICIENT COOLING

HIGH DISCHARGE PRESSURE AND/OR HIGH SUCTION PRESSURE

DISCHARGE PRESSURE LOW AND/OR SUCTION PRESSURE LOW

CHECK THE SIGHT GLASS

INSPECT THE SIGHT GLASS

EXCESS REFRIGERANT IN SYSTEM

BUBBLES VISIBLE IN SIGHT GLASS Insufficient quantity of refrigerant in system. Possibly due to small leaks. 1. Check system for leaks and eliminate if found. 2. Add refrigerant until the bubbles disappear and both pressure gauges indicate normal pressure.

Note: the sight glass may contain bubbles. Evacuate refrigerant until a large number of bubbles appear in the sight glass, then add refrigerant to the system until the bubbles disappear

CONDENSER 1. Fins could be clogged thus restricting the flow of air over the condenser. Clean condenser fins. 2. The condenser must be positioned at the distance from the radiator specified in the system design. EXPANSION VALVE Check the valve as previously described. 1.If the valve fails the test, replace it.

DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL

Note: During testing, the low pressure gauge reading could fall to negative values or remain normal. HUMIDITY IN SYSTEM 1. Evacuate the refrigerant from the system. 2. Replace the receiver--dryer. 3. Bleed air from the system then re--charge.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 TROUBLESHOOTING (cont.) INSUFFICIENT COOLING

HIGH DISCHARGE PRESSURE AND/OR NORMAL SUCTION PRESSURE

DISCHARGE PRESSURE HIGH AND/OR SUCTION PRESSURE LOW

DISCHARGE PRESSURE NORMAL AND/OR SUCTION PRESSURE NORMAL/ HIGH

Note: The pressure reading of the high pressure gauge should be constant without any decrease.

OBSTRUCTION Water or ice forms downstream of the obstruction (on receiver--dryer or on the pipe between the condenser outlet and the expansion valve). 1.Remove the component and eliminate the obstruction.

ANTI--FROST SWITCH With ambient temperature below 30 _C (86 _F) the electromagnetic clutch is permanently engaged. 1. Check as described in appropriate section. 2.Replace the anti--frost switch (1, fig. 14). If it does not function correctly, being careful not to crush the capillary tube, install new switch in the same position and depth inside the evaporator as the previous switch.

AIR IN SYSTEM 1. Recover--recycle the refrigerant in the system. 2. Replace the receiver--dryer. 3. Evacuate the system and then recharge.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

TROUBLESHOOTING (cont.) COMPRESSOR AND ELECTROMAGNETIC CLUTCH

ABNORMAL NOISE WHEN CLUTCH ENGAGED

NO COOLING

1. Check all compressor mountings. 2. Check engine components in the vicinity of the compressor. 3. Check if the electromagnetic clutch operates intermittently or slips.

The compressor runs noisily or does not run.

4. Check the clutch bearing. 5. Check that the electromagnetic clutch pulley runs smoothly. 6. Check the oil level in the compressor.

1. Check the condition and tension of the compressor drive belt 2. Check the clearance between the front disc and the pulley of the electromagnetic clutch. 3. Check the clutch supply voltage, the current draw, the supply lead, and proper grounding.

4. Check that the electromagnetic clutch pulley runs smoothly. 5. Check that there is a sufficient quantity of refrigerant in the system. 6. Check the compressor for leaks. 7. Check the system for leaks.

ABNORMAL NOISE WITH CLUTCH DISENGAGED OR VIBRATION

1. Check electrical power supply. 2. Check the clearance between the front disc and the pulley.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

OVERHAUL AIR CONDITIONING AND HEATING PIPES Removal

DANGER

When recovering refrigerant from the system adhere to applicable safety precautions. 1. Disconnect the negative battery lead. 2. Recover the refrigerant from the system using the recovery/recycling station 380000559 as described previously. 3. Drain off approximately 3 liters (3 quarts) of coolant from the drain plug (1) on the engine block.

4. Remove the 4 cab roof retaining bolts (1).

TRE0124A

5. Remove the cab roof as shown in the figure 35.

TRE0152A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

6. Remove plate fastening screws and take of the plate (1)

1 TRE0155A

7. Remove A/C assembly fastening screws (1).

TRE0225A

8. Remove A/C inlet and outlet pipes (1).Remove front retaining screws (2).

2 1

TRE0224A

9. Remove heater pipe connections (1) and take off the pipes.

TRE0226A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

10. Remove the bracket (1) that secures the pipe.

TRE0227A

11. Remove all electric connectors and take off the A/C assembly (1) completely.

TRE0228A

12. A/C assembly is shown in figure 42.

TRE0223A

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 Installation 1. Clean all parts. 2. Install A/C assembly completely and connect all electrical connectors. 3. Assemble the bracket that secures the heater pipe. 4. Assemble the heater pipe connections then install. 5. Install A/C assembly inlet & outlet pipes. 6. Install A/C assembly fastening screws. 7. Install top cover plate. 8. Assemble the cab roof. 9. Install the 4 cab roof retaining bolts. 10. Pour the previously drained coolant back into the radiator. 11. Connect the negative battery lead. 12. Charge the air conditioning system with HRC 134 a refrigerant, using the evacuation/ charging station 380000558 as previously described.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

RECEIVER--DRYER Removal

DANGER

When recovering the refrigerant from the system adhere to applicable safety precaution. 1. Recover the refrigerant from the system using station 380000559 as described earlier. 2. Detach the exhaust pipe and raise the hood. 3. Disconnect the negative battery lead. 4. Disconnect the electrical connector (1) from the receiver--dryer.

24887

5. Detach the flexible pipe (1) connecting the condenser to the receiver--dryer.

24888

6. Detach the flexible pipe (1) connecting the receiver--dryer to the evaporator.

24889

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2 7. Remove the screw (1) securing the receiver--dryer band clamp.

24890

8. Remove the complete receiver--dryer (1).

24891

Installation 1. Replace the receiver--dryer in the support clamp. 2. Connect the two flexible return and delivery pipes. 3. Connect the electrical connections on the filter. 4. Connect the negative battery lead. 5. Evacuate the system then charge with HRC 134a refrigerant, using the evacuation/charging station 380000558, as described on page 23. 6. Attach the exhaust pipe and close the hood.

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

CONDENSER

Removal

DANGER

Recover the refrigerant from the system adhering to the applicable safety precaution.

1. Disconnect the negative battery lead. 2. Recover the refrigerant from the system using the station 380000559 as previously described. 3. Detach the flexible refrigerant delivery and return pipes (1) from the condenser.

1 24892

4. Unscrew the wingnut (1) securing the condenser.

24893

5. For tractors equipped with front mudguards, remove the two screws (1) securing the top bracket of the condenser. For tractors without front mudguards, turn the steering wheel to the full righthand position

24894

6. For tractors with front mudguards, remove the condenser group (1) with the top bracket. For tractors without front mudguards, remove the condenser from the right-hand side of the tractor.

Installation 1. Install the condenser and the relative bracket, and secure the condenser with the wingnut and the bracket with the two retaining screws. 2. Reconnect the two flexible pipes to the condenser. 3. Connect the negative battery lead. 4. Evacuate the air conditioning system and charge with HRC 134 a refrigerant, using the evacuation/ charging station 294030 as described earlier. 5. Close the hood.

24895

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

COMPRESSOR Removal

DANGER

Recover the refrigerant from the system adhering to applicable safety precautions. 1. Recover the refrigerant from the system using station 380000559 as previously described. 2. Raise the hood. 3. Disconnect the negative battery lead. 4. Disconnect the flexible pipes (1) from the compressor.

TRE0838A

5. Remove the right--hand guard retaining screws (1).

24903

53 6. Remove the two securing nuts (1) of the compressor belt tensioner arm.

24904

7. Disconnect the earth lead (1) from the compressor.

24905

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

8. Loosen the bolt (1) securing the compressor to the engine and remove the drive belt from the pulleys.

24906

56 9. Remove the compressor bolt (1) and recover the compressor.

Installation 1. Install the compressor and the support/belt tensioner arm. 2. Connect the earth (ground) lead from the compressor. 3. Install the right--hand guard. 4. Connect the two flexible pipes to the compressor. 5. Connect the negative battery lead. 6. Evacuate the air conditioning system and charge with HRC 134 a refrigerant, using the evacuation/charging station 380000558 as previously described. 7. Close the hood.

COMPRESSOR OIL -TYPE AND QUANTITY The tractor is equipped with a SANDEN SD 7H15 compressor for refrigerant R134a. The compressor is filled during assembly with 185cm3 (6.2 oz) of PAG SP 20 lubricating oil. In the event that oil needs to be changed or added use this type of oil. It is not necessary to check the compressor oil level unless the system develops significant gas leaks. NOTE: If the system develops significant leaks of R134a refrigerant, there will also be a significant loss of compressor oil PAG SP20. It will therefore be necessary to check the compressor oil level, bearing in mind that, on average, only 130 to 135 cm 3 (4.4 to 4.5 oz), of the total quantity of lubricating oil (185 cm 3) [6.2 oz]) will be present in the compressor, as the remaining 50 to 55 cm 3 (1.7 to 1.8 oz) will be in circulation through the various system components. For problems of this type, we recommend that you seek assistance from an authorized dealer.

24907

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2

ADJUSTMENTS COMPRESSOR DRIVE BELT 12 to 13 mm (.472 to .511 in)

Tension Adjustment The tension and condition of the belt transmitting drive from the engine to the compressor is particularly important with regards to the correct operation of the air conditioning system. This drive belt therefore requires careful attention as follows: 23927

1) Fit the belt correctly. 2) Check the tension. 3) Check the condition of the belt.

Fitting the Compressor Drive Belt When first fitted, the belt must not be forced, pulled with a screwdriver, or rolled over the edge of the pulley, as this would stretch the less deformable fabric in the belt thus causing subsequent breakage of the other fabrics. When first fitted, the belt must be installed at a greater tension than normal to compensate for initial stretching during the running--in period. The belt must therefore be checked again after 50 hours of operation and adjusted to the normal tension.

58 Periodic Checking of Drive Belt When checking the tension, also check the amount of drive belt wear. The main problems are as follows: a) Belt shiny : smooth sides may slip on pulleys. Corrective action may include adjusting the belt to proper tension or replacement. b) Belt cracked : may break suddenly due to splits on the inner surface caused by excessive flexure. If cracks are excessive, the belt should be replaced. c) Worn sides : with the sides worn or the inner surface cracked, the belt can break at any moment. Belt should be replaced

This check is absolutely essential as if the belt is too taut, in addition to damaging the pulley bearings, it will cause premature fatigue of the reinforcement fabrics and thus early deterioration.

d) Belt impregnated with grease : the belt will wear more rapidly as the grease will cause softening. this condition will be evidenced by proper belt tension, yet belt extremely hot.

If on the contrary the belt is too slack, it will start to slip and overheat, and it will therefore wear out prematurely.

If the belt squeaks when running, check the tension and adjust if necessary. If the noise continues, replace the belt.

Checking Compressor Drive Belt Tension Check the tension only when the belt is cool (at a temperature below a 40 0C [104 0F]).

If the belt has been over--stretched and it is not possible to tension it sufficiently, replace it.

Check the tension by applying a load of 78 to 98 N (7.5 to 22 lb force) to the center of the belt run indicated in the figure: the belt should deflect â&#x2030;&#x2026; 12 to 13 mm (0.472 to 0.511 ins).

SECTION 90 -- PLATFORM, CAB, BODYWORK AND DECALS -- CHAPTER 2