New Holland Tractor TL60E, TL75E, TL85E, TL95E Service Manual 47835583 - PDF DOWNLOAD by www.heydownloads.com

SERVICE MANUAL

SERVICE MANUAL TL60E / TL75E / TL85E / TL95E Tractor

TL60E TL75E TL85E TL95E Tractor

1/2 Part number 47835583

Part number 47835583 English October 2015

SERVICE MANUAL TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015 EN

Link Product / Engine Product TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E 12x4, 4WD, cabine nova [HCCZTL60CFC438464 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL60E Sem cabine, 12x4, 4WD [ZDCL05524 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x4, 2WD, cabine nova [HCCZTL75CFC438464 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ] TL75E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC437744 - ]

Market Product Australia New Zealand

8035.05.716

Latin America

8035.05.716

Asia Pacific

8035.05.716

Middle East Africa

8035.05.716

North America

8035.05.716

Europe

8035.05.716

Asia Pacific

8035.05.716

Middle East Africa

8035.05.716

Australia New Zealand

8035.05.716

Latin America

8035.05.716

North America

8035.05.716

Europe

8035.05.716

Asia Pacific

8045.05.260

Latin America

8045.05.260

Australia New Zealand

8045.05.260

Middle East Africa

8045.05.260

Europe

8045.05.260

North America

8045.05.260

Middle East Africa

8045.05.260

Latin America

8045.05.260

Europe

8045.05.260

Asia Pacific

8045.05.260

Australia New Zealand

8045.05.260

North America

8045.05.260

47835583 21/10/2015

Engine

Product TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 4WD [ZDCL04468 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E Sem cabine, 2WD [ZEC134399 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x4, 12x12, 2WD, cabine nova [HCCZTL85CFC437744 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, cabine nova [HCCZTL75CFC438464 - ] TL95E Sem cabine, 4WD [ZDC112512 - ] TL95E Sem cabine, 4WD [ZDC112512 - ]

Market Product Latin America

8045.25.260

Europe

8045.25.260

Australia New Zealand

8045.25.260

Asia Pacific

8045.25.260

North America

8045.25.260

Middle East Africa

8045.25.260

North America

8045.25.260

Asia Pacific

8045.25.260

Australia New Zealand

8045.25.260

Latin America

8045.25.260

Middle East Africa

8045.25.260

Europe

8045.25.260

Europe

8045.25.260

Middle East Africa

8045.25.260

Australia New Zealand

8045.25.260

North America

8045.25.260

Latin America

8045.25.260

Asia Pacific

8045.25.260

Latin America

8045.25.260

Asia Pacific

8045.25.260

Australia New Zealand

8045.25.260

Europe

8045.25.260

North America

8045.25.260

Middle East Africa

8045.25.260

Asia Pacific

8045.25.262

Europe

8045.25.262

47835583 21/10/2015

Engine

Product TL95E Sem cabine, 4WD [ZDC112512 - ] TL95E Sem cabine, 4WD [ZDC112512 - ] TL95E Sem cabine, 4WD [ZDC112512 - ] TL95E Sem cabine, 4WD [ZDC112512 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ] TL95E 12x12, 20x12, 4WD, cabine nova [HCCZTL95EFC438464 - ]

Market Product North America

8045.25.262

Latin America

8045.25.262

Middle East Africa

8045.25.262

Australia New Zealand

8045.25.262

Europe

8045.25.262

Australia New Zealand

8045.25.262

Middle East Africa

8045.25.262

Asia Pacific

8045.25.262

North America

8045.25.262

Latin America

8045.25.262

47835583 21/10/2015

Engine

Contents INTRODUCTION Engine....................................................................................... 10 [10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

Clutch ....................................................................................... 18 [18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

Transmission.............................................................................. 21 [21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.162] Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

Four-Wheel Drive (4WD) system .................................................. 23 [23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3

Front axle system ....................................................................... 25 [25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

47835583 21/10/2015

Rear axle system........................................................................ 27 [27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

Power Take-Off (PTO) ................................................................. 31 [31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.110] One-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 [31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4

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

Hydraulic systems....................................................................... 35 [35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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

Frames and ballasting ................................................................. 39 [39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

Steering..................................................................................... 41 [41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3 47835583 21/10/2015

Wheels ...................................................................................... 44 [44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

Cab climate control ..................................................................... 50 [50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

Electrical systems ....................................................................... 55 [55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.030] Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

Platform, cab, bodywork, and decals ............................................. 90 [90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6

47835583 21/10/2015

INTRODUCTION

47835583 21/10/2015

Contents INTRODUCTION International symbols (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Foreword - Important notice regarding equipment servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Foreword - How to use and navigate through this manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Safety rules - Ecology and the environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Safety rules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Torque - Minimum tightening torques for normal assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Basic instructions â&#x20AC;&#x201D; Shop and assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Torque â&#x20AC;&#x201D; Standard torque data for hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

(*) See content for specific models 47835583 21/10/2015

INTRODUCTION

International symbols TL60E TL75E TL85E TL95E

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

Turning signal

Power Take-Off (PTO)

Reaction control

Alternator charging

Activated memory

Transmission in neutral

Accessories socket

Fuel level

Turn signals

Creeper selection

Implement socket

Automatic fuel shut-off

Turn signals - one trailer

Low speed selection

Percentage slip

Engine speed (rpm x 100)

Turn signals - two trailers

High speed selection

Raising of the hydraulic lift

Hour meter

Wind shield washer

Road speed

Rear hitch lower

Engine oil pressure

Windscreen wash wipe

Differential Lock

Hydraulic lift height threshold

Engine coolant temperature

Heating temperature control

Rear axle oil temperature

Hydraulic lift disabled

Coolant level

Cab recirculation fan

Transmission oil pressure

Transmission filters and hydraulic filters

Machine lights

Air conditioner

Auxiliary Front Wheel Drive (AFWD) operated

Remote control valve extension

Main beam head

Air Filter Restriction

Warning!

Remote control valve command retraction

Low beam

Parking brake

Danger warning lights

Remote control valve flotation

Work lamps

Brake fluid level

Variable control

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

Stop lamp

Trailer brake

Pressurized! Open carefully

Malfunction! (alternative symbol)

Klaxon

Warning! Corrosive substance

Position control

Brake fluid level

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Foreword - Important notice regarding equipment servicing All repair and maintenance work listed in this manual must be carried out only by qualified dealership personnel, strictly complying with the instructions given, and using, whenever possible, the special tools. Anyone who performs repair and maintenance operations without complying with the procedures provided herein shall be responsible for any subsequent damages. The manufacturer and all the organizations of its distribution chain, including - without limitation - national, regional, or local dealers, reject any responsibility for damages caused by parts and/or components not approved by the manufacturer, including those used for the servicing or repair of the product manufactured or marketed by the manufacturer. In any case, no warranty is given or attributed on the product manufactured or marketed by the manufacturer in case of damages caused by parts and/or components not approved by the manufacturer. The manufacturer reserves the right to make improvements in design and changes in specifications at any time without notice and without incurring any obligation to install them on units previously sold. Specifications, descriptions, and illustrative material herein are as accurate as known at time of publication but are subject to change without notice. In case of questions, refer to your NEW HOLLAND Sales and Service Networks.

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Foreword - How to use and navigate through this manual This manual has been produced by a new technical information system. This new system is designed to deliver technical information electronically through web delivery (eTIM), DVD, and paper manuals. A coding system called SAP has been developed to link the technical information to other Product Support functions, e.g., Warranty. Technical information is written to support the maintenance and service of the functions or systems on a customer's machine. When a customer has a concern on their machine it is usually because a function or system on their machine is not working at all, is not working efficiently, or is not responding correctly to their commands. When you refer to the technical information in this manual to resolve that customer's concern, you will find all the information classified using the SAP coding, according to the functions or systems on that machine. Once you have located the technical information for that function or system, you will then find all the mechanical, electrical or hydraulic devices, components, assemblies, and sub assemblies for that function or system. You will also find all the types of information that have been written for that function or system: the technical data (specifications), the functional data (how it works), the diagnostic data (fault codes and troubleshooting), and the service data (remove, install adjust, etc.). By integrating SAP coding into technical information, you will be able to search and retrieve just the right piece of technical information you need to resolve that customer's concern on his machine. This is made possible by attaching 3 categories to each piece of technical information during the authoring process. The first category is the Location, the second category is the Information Type and the third category is the Product: • LOCATION - the component or function on the machine, that the piece of technical information is going to describe (e.g., Fuel tank). • INFORMATION TYPE - the piece of technical information that has been written for a particular component or function on the machine (e.g., Capacity would be a type of Technical Data describing the amount of fuel held by the fuel tank). • PRODUCT - the model for which the piece of technical information is written. Every piece of technical information will have those three categories attached to it. You will be able to use any combination of those categories to find the right piece of technical information you need to resolve that customer's concern on their machine. That information could be: • the procedure for how to remove the cylinder head • a table of specifications for a hydraulic pump • a fault code • a troubleshooting table • a special tool

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Manual content This manual is divided into Sections. Each Section is then divided into Chapters. Contents pages are included at the beginning of the manual, then inside every Section and inside every Chapter. An alphabetical Index is included at the end of each Chapter. Page number references are included for every piece of technical information listed in the Chapter Contents or Chapter Index. Each Chapter is divided into four Information types: • Technical Data (specifications) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Functional Data (how it works) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Diagnostic Data (fault codes, electrical and hydraulic troubleshooting) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies. • Service Data (remove disassemble, assemble, install) for all the mechanical, electrical or hydraulic devices, components, assemblies or sub-assemblies.

Sections Sections are grouped according to the main functions or a systems on the machine. Each Section is identified by a number (00, 35, 55, etc.). The Sections included in the manual will depend on the type and function of the machine that the manual is written for. Each Section has a Contents page listed in alphabetic/numeric order. This table illustrates which Sections could be included in a manual for a particular product. PRODUCT Tractors Vehicles with working arms: backhoes, excavators, skid steers, …. Combines, forage harvesters, balers, …. Seeding, planting, floating, spraying equipment, …. Mounted equipment and tools, …. X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X X

SECTION 00 - Maintenance 05 - Machine completion and equipment 10 - Engine 14 - Main gearbox and drive 18 - Clutch 21 - Transmission 23 - Four wheel drive (4WD) system 25 - Front axle system 27 - Rear axle system 29 - Hydrostatic drive 31 - Power Take-Off (PTO) 33 - Brakes and controls 35 - Hydraulic systems 36 - Pneumatic system 37 - Hitches, drawbars and implement couplings 39 - Frames and ballasting 41 - Steering 44 - Wheels 46 - Steering clutches 48 - Tracks and track suspension 50 - Cab climate control 55 - Electrical systems 56 - Grape harvester shaking 58 - Attachments/headers 60 - Product feeding

X X X X X X X X X X X X X X

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61 - Metering system 62 - Pressing - Bale formation 63 - Chemical applicators 64 - Chopping 66 - Threshing 68 - Tying/Wrapping/Twisting 69 - Bale wagons 70 - Ejection 71 - Lubrication system 72 - Separation 73 - Residue handling 74 - Cleaning 75 - Soil preparation/Finishing 76 - Secondary cleaning / Destemmer 77 - Seeding 78 - Spraying 79 - Planting 80 - Crop storage / Unloading 82 - Front loader and bucket 83 - Telescopic single arm 84 - Booms, dippers and buckets 86 - Dozer blade and arm 88 - Accessories 89 - Tools 90 - Platform, cab, bodywork and decals

X X X X X X X X X X X X X X X

X X X X X X X X X X

X X X X X X X X X X X X X X X X

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Chapters Each Chapter is identified by a number e.g. Engine - Engine and crankcase - 10.001. The first number is identical to the Section number i.e. Chapter 10.001 is inside Section 10, Engine. The second number is representative of the Chapter contained within the Section. CONTENTS The Chapter Contents lists all the technical data (specifications), functional data (how it works), diagnostic data (fault codes and troubleshooting), and service data (remove, install, adjust, etc.), that have been written in that Chapter for that function or system on the machine. Contents ENGINE ENGINE - Engine and crankcase â&#x20AC;&#x201C; 10.001 TECHNICAL DATA ENGINE - Engine and crankcase - General specification (10.001 - D.40.A.10)

FUNCTIONAL DATA ENGINE - Engine and crankcase - Dynamic description (10.001 - C.30.A.10)

SERVICE ENGINE - Engine and crankcase - Remove (10.001 -F.10.A.10)

DIAGNOSTIC ENGINE - Engine and crankcase - Troubleshooting (10.001 - G.40.A.10)

INDEX The Chapter Index lists in alphabetical order all the types of information (called information units) that have been written in that Chapter for that function or system on the machine. Index ENGINE - 10 ENGINE ENGINE - Engine and crankcase - Dynamic description (10.001 - C.30.A.10)

ENGINE - Engine and crankcase - General specification (10.001 - D.40.A.10)

ENGINE - Engine and crankcase - Remove (10.001 -F.10.A.10)

ENGINE - Engine and crankcase - Troubleshooting (10.001 - G.40.A.10)

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Information units and information search Each chapter is composed of information units. Each information unit has the SAP code shown in parentheses. This indicates the function and type of information in that information unit. Each information unit has a page reference within that Chapter. The information units provide a quick and easy way to find just the right piece of technical information you are looking for. Example information Engine block cover - Front – Remove (10.102.AP.01 - F.10.A.10) unit 10 102 AK 01 F 10.A.10 Information Unit SAP code Pan and covers Engine block Front SAP code classification Engine Service data Remove cover

NHIL12GEN0070A

Navigate to the correct information unit you are searching for by identifying the function and information type from the SAP code. • (1) Location and (2) Information type. • (A) corresponds to the sections of the service manual. (B) corresponds to the chapters of the service manual. After (B) there may be some additional information. In this case it shows “.01”, which represents the “Front” block cover. These options may be front/rear, left/right, hydraulic/ mechanical etc. (C) corresponds to the type of information listed in the chapter contents: Technical Data, Functional Data, Diagnostic, or Service. (A) and (B) are also shown in the page numbering on the page footer. THE REST OF THE CODING IS NOT LISTED IN ALPHANUMERIC ORDER IN THIS MANUAL. • You will find a table of contents at the beginning and end of each section and chapter. You will find an alphabetical index at the end of each chapter. • By referring to (A), (B) and (C) of the coding, you can follow the contents or index (page numbers) and quickly find the information you are looking for.

Page header and footer The page header will contain the following references: • Section and Chapter description The page footer will contain the following references: • Publication number for that Manual. • Version reference for that publication. • Publication date • Section, chapter, and page reference e.g. 10.102 / 9

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Safety rules General safety regulations General Aspects • Strictly follow repair and maintenance procedures. • Do not wear rings, wrist watches, jewelry, accessories, unbuttoned items of clothing, unsecured clothing like ties, torn clothing, scarves, or open jackets or shirts with open zippers that could get caught in moving parts. Use approved safety clothing, such as anti-slip footwear, sleeves, protective goggles, helmets, etc. • Wear safety goggles with side shields when cleaning parts using compressed air. • Worn or damaged cables and chains are not reliable. Do not use these elements in lifting or towing operations. • Use regulation safety equipment, such as approved eye protection, helmets, clothes, sleeves, and special footwear whenever you are welding. All individuals near the welding process must use regulation eye protection. Never look at the welding arc without using suitable eye protection. • Never perform any repairs on the machine if there is someone in the operator seat, except when the person is a qualified operator who is helping with the service to be performed. • Never operate the machine or use accessories from a place other than the operator seat or next to the machine when operating the fender switches. • Never perform any operations on the machine with the engine running, except when specifically instructed to do so. Shut down the engine and release all the pressure from the hydraulic circuits before removing covers, cases, valves, etc. • You must conduct all repair and maintenance operations with the utmost care and attention. • Disconnect the batteries and put warning labels on all of the controls to warn that the machine is being repaired. Lock the machine and all the equipment that you remove. • Never check or fill the fuel tank or batteries or use starting fluid when you are smoking or near a naked flame, because these fluids are flammable. • The fuel filling gun must remain in contact with the filler neck. Maintain the contact until the fuel stops flowing into the tank in order to avoid sparks caused by static electricity build-up. • To transport a faulty machine, use a trailer or a low loader platform trolley, if available. • To load and unload the machine from the mode of transportation, choose a flat area that offers firm support for the wheels of the truck or trailer. Securely fasten the machine to the platform of the trailer or truck, in accordance with the transporter’s requirements. • Always use hoist mechanisms with an appropriate capacity for lifting or moving heavy components. • Chains must always be securely fastened. The fastening device must have sufficient capacity to support the intended load. It is prohibited for bystanders to be near the fastening position. • The work area must always be clean and dry. Clean it immediately if any water or oil is spilled. • Never use gasoline, diesel, or other flammable liquids for cleaning. Use only non-toxic solvents. • Do not allow cloths soaked with oil or grease to accumulate because they can cause a fire risk. Always keep these cloths in a metal container.

Starting • Never start the engine in enclosed spaces that are not equipped with a suitable exhaust system or gas-extraction system. • Never bring your head, body, arms, legs, feet, hands, or fingers close to fans or rotating belts.

Engine • Always loosen the radiator cap slowly before removing it, in order to dissipate the system pressure. You must top up the coolant with the engine stopped. • Do not fill up the fuel tank when the engine is running. • Never adjust the fuel injection pump when the machine is in motion. 47835583 21/10/2015

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• Never lubricate the machine when the engine is running.

Electrical systems • If it is necessary to use auxiliary batteries, you must connect the cables on both sides as follows: (+) to (+) and (-) to (-). Avoid causing the terminals to short circuit. The gas that the batteries release is highly flammable. During charging, leave the battery compartment open to improve ventilation. Avoid sparks and naked flames near the battery. Do not smoke. • Do not charge the batteries in enclosed spaces. • Always disconnect the batteries before carrying out any type of servicing on the electrical system.

Hydraulic system • A little fluid coming out of a small bore could be almost invisible, but strong enough to penetrate the skin. For this reason, never use your hands to check for leaks. Instead, use a piece of cardboard or wood. If any fluid penetrates your skin, seek medical assistance immediately. Failure to seek immediate medical assistance could result in serious infections or dermatitis. • Always read the system pressure using suitable gauges.

Wheels and tires • Make sure that the tires are correctly inflated at the pressure specified by the manufacturer. Inspect the rims and tires regularly for any damage. • Remain next to the tire when filling it with air. • Only check the pressure when the platform is unloaded and the tires are cold, in order to prevent inaccurate readings caused by overpressure. • Never cut or weld a rim with a full tire fitted. • To remove the wheels, lock both the front and rear wheels of the machine. Lift the machine. Install stable and secure supports under the machine, as per the legislation in force. • Deflate the tire before removing any objects that may be caught in the tire tread. • Never inflate tires using flammable gases, as they could cause explosions and injure bystanders.

Remove and install • Lift and handle all heavy components using hoist devices of appropriate capacity. You must suspend the parts using suitable hooks and slings. Use the hoist eyes provided for this purpose. Be careful if there are any bystanders near the hoisted load.

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Safety rules Health and safety precautions Many of the procedures involved in machine maintenance and repair services involve physical hazards and other health risks. This section lists some of these hazardous procedures and the materials and equipment associated with them.

Acids and alkalis Avoid splashing into your eyes and nose, or onto your skin and clothing. Wear suitable sleeves and protective goggles. Irritate and corrode the skin, eyes, nose, and throat. Causes burns. Do not inhale the fumes.

Adhesives and sealants These are highly flammable. You must store them in no smoking areas. Use applicators when possible or secondary containers. The containers must be labeled.

Resin-based adhesives/sealants Skin contact could result in irritation, dermatitis, and the absorption of toxic or harmful chemicals through the skin. Splashes could cause eye injuries. Ensure that there is adequate ventilation and avoid contact with the skin and the eyes. Follow the manufacturerâ&#x20AC;&#x2122;s instructions. Ensure that there is adequate ventilation as volatile harmful or toxic chemicals may be released.

Anti-freeze These are highly flammable. You must store them in no smoking areas. Anti-freeze can be absorbed through the skin in toxic or harmful quantities. Ingesting anti-freeze can cause death and you must seek medical assistance immediately.

Chemicals â&#x20AC;&#x201C; General You must always take care when using and handling chemicals such as solvents, sealants, adhesives, paints, foam resins, battery acids, anti-freeze, brake fluid, oils and greases. They may be harmful, toxic, corrosive, irritant, or highly flammable. They may also emit hazardous fumes or dust.

Do Remove chemicals from skin and clothing as soon as possible after contact. Change very dirty clothes and make provision for cleaning them. Read and strictly adhere to the safety recommendations on the chemical containers. When working with chemicals, wash before breaks, and before eating, smoking, drinking, or using the bathroom. Keep work areas clean, organized, and free of spillages. Store according to local and national legislation. Keep chemicals out of the reach of children.

Do not Do not mix chemicals, except in accordance with the manufacturer's instructions. Some substances could form other chemical substances that are toxic or harmful, emit toxic or harmful fumes, or become explosive after mixing. Do not spray chemicals, especially solvent-based chemicals, in enclosed spaces. Do not apply heat or flames to chemicals, except in accordance with the manufacturer's instructions. Some are highly flammable or could release toxic or harmful fumes. Do not leave containers open. The fumes emitted could accumulate in toxic, harmful, or explosive concentrations. Some fumes are heavier than air and will accumulate in confined areas, trenches, etc. Do not put chemicals in unmarked containers. 47835583 21/10/2015

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Do not clean your hands or clothes with chemicals. Chemicals, particularly solvents and fuels, dry out the skin and can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Do not use empty containers to store other chemicals, except when they have been cleaned under supervision. Do not attempt to sniff or inhale chemicals. Rapid exposure to high concentrations of fumes can be toxic or harmful.

Anti-corrosive protective material These materials are varied and you must follow the manufacturers' instructions. They may contain solvents, resins, petroleum derivatives, etc. You must avoid contact with the skin and the eyes. You must carry out spraying with adequate ventilation and never in enclosed spaces.

Post Dust, powders, or clouds may be irritant, harmful, or toxic. Avoid inhaling the chemical powders or dusts that result from dry abrasion services. Use respiratory protection if ventilation is not adequate.

Electric shock Electric shocks result from the use of faulty electrical equipment or from incorrect use. You must keep electrical equipment in good condition and test it frequently. Electrical equipment must be protected by a fuse with an appropriate nominal capacity. Use low-voltage equipment ( 110 volt) for work lights and inspection lights, wherever possible. Use pneumatic equipment instead of electrical equipment wherever possible. In the event of electrocution: • Turn off the electricity before approaching the victim. • If that is not possible, push or pull the victim away from the source of the electricity using a dry, non-conductive material. • If you have been trained, start giving first aid. • Seek medical assistance.

Exhaust fumes These fumes contain asphyxiating, toxic or harmful chemical substances. You must only run engines in adequate extraction or general ventilation conditions, and never in enclosed spaces.

Fiber insulation The fibrous nature of cut surfaces and edges can cause skin irritation. In general, the effect is physical and not chemical. You must take precautions to avoid excessive skin contact. Take care when organizing your work methods. Wear sleeves.

Fire Many materials relating to vehicle repair are highly flammable. Some release toxic or harmful fumes when burned. Scrupulously observe the fire prevention safety recommendations when storing and handling flammable materials or solvents, particularly in the vicinity of electrical equipment or welding processes. Before using any electrical or welding equipment, ensure that there is no risk of fire. Always have an appropriate fire extinguisher nearby when using welding or heating equipment.

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Foams â&#x20AC;&#x201C; Polyurethane See fire. Used for soundproofing. Cured foams used in seat cushions and finishes. Follow the manufacturerâ&#x20AC;&#x2122;s instructions. Components that have not reacted are irritants and could be harmful to the eyes and the skin. Wear sleeves and protective goggles. Individuals with chronic respiratory illnesses, asthma, bronchial problems, or a history of allergic illnesses must not work with or be in proximity to uncured materials. Components, fumes, and aerosol clouds can cause irritation and sensitization reactions, and may be toxic or harmful. You must apply these materials with adequate respiratory protection and adequate ventilation. Do not remove the respirator when you have finished spraying. Keep the respirator on until the fumes and clouds disperse. Burning uncured components and cured foams can generate toxic and harmful fumes. Do not permit smoking, the presence of naked flames, or the use of electrical equipment during the application of foam, and until the fumes/ clouds have dispersed. The hot cutting of cured or partially cured foam must be performed in an environment with a ventilation system with extraction.

Kerosene (Paraffin) Ingesting kerosene can cause irritation to the mouth and throat. The greatest danger from ingesting kerosene is the possibility of breathing it into the lungs. Liquid contact dries the skin and can cause irritation or dermatitis. Splashes on the skin and in the eyes cause mild irritation. Avoid contact with the eyes and the skin as far as possible and ensure that there is adequate ventilation.

Fuel oil (diesel fuel) When the quantities are large or the exposure period is long, skin contact with fuel oils with a high boiling point can cause serious skin diseases, including skin cancer.

Gas cylinders See fire. In general, gases, such as oxygen, carbon dioxide, argon, and propane, are stored in cylinders with pressures of up to 140 bar ( 2000 lb/in2). You need to take sufficient care when handling them to prevent physical damage to the cylinders and the valve accessories. The content of each cylinder must be clearly identified with suitable labels. You must store the cylinders in a well-ventilated room, protected from ice, rain, and direct sunlight. You must not store combustible gases near to oxygen cylinders. Be careful to prevent leaks from the cylinders and the gas lines, and to avoid ignition sources. Only qualified personnel may perform services using the cylinders.

General workshop equipment and tools You must keep all equipment and tools in good condition and you must use the correct safety equipment whenever necessary. Never use tools or equipment for any purpose other than that for which they are intended. Never overload equipment such as hoists, jacks, chassis bases and axles, or hoisting slings. The damage caused by overloading does not always appear immediately and could cause a fatal accident the next time that the equipment is used. Do not use faulty or damaged equipment or tools, particularly high-speed equipment, such as emery wheels. A damaged emery wheel can disintegrate suddenly and cause serious injury. Use protective goggles whenever you use equipment for grinding, cutting, polishing, or sandblasting.

Oil test equipment, lubrication test equipment, and high-pressure air test equipment, in accordance with local legislation Always keep high-pressure equipment in good condition and carry out regular maintenance, particularly on connections and fittings. Never point a high-pressure nozzle at the skin as the fluid can cause serious injuries.

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Legal aspects Various laws and regulations lay down the health and safety requirements for working with materials and equipment in workshops. Always observe the regulations and laws in force in the country in which you are working. Workshops must comply with the relevant regulations and laws. Consult the local supervisory authorities or related government bodies if you are in any doubt.

Lubricants and greases Avoid prolonged or recurrent contact with mineral oils, particularly used oils. Thoroughly wash the skin after tasks using oil. Do not use gasoline, paraffin, or other solvents to remove oil from the skin. Lubricants and greases can cause mild eye irritation. You must avoid repeated or prolonged skin contact by wearing protective clothing where necessary. Do not allow your work clothes to become contaminated with oil. Wash or dry clean work clothes regularly. Discard oil-soaked shoes. Do not use used engine oil as a lubricant or for applications where it might come into contact with the skin.

Paints You should preferably perform spraying in a ventilated cab with an exhaust system to remove the fumes and spray from the breathing area. Individuals working in cabs must use respiratory protection. Personnel carrying out smallscale repair work must use respirators with an air supply.

Solvents Contact dries out the skin, and prolonged or recurrent contact can cause irritation and dermatitis. Some can be absorbed through the skin in toxic or harmful quantities. Splashes into the eyes can cause serious irritation and even lead to blindness. Wear protective sleeves, protective goggles and protective clothing. Ensure that there is good ventilation during use, avoid inhaling smoke, fumes, and spray clouds, and keep containers securely closed. Do not use in enclosed spaces. Do not apply heat or flame, except in accordance with specific and detailed instructions from the manufacturer.

Arc welding This process emits a high level of ultraviolet radiation that can burn the eyes and skin of the welder and of other people nearby. Gas-protected welding processes are particularly dangerous in this respect. Personal protection is mandatory. Barriers to protect other people are also necessary. You also need to use suitable eye and skin protection because of metal splashes. The heat of arc welding will produce gases and fumes from the metals that are being melted, and from the coatings applied to or contamination on the worked surfaces. These gases and fumes may be toxic and you must avoid inhaling them. You may need to use ventilation with extraction to remove smoke from the work area, particularly in cases where there is not enough general ventilation or in places where a considerable amount of welding is expected to take place. In extreme cases, where adequate ventilation cannot be guaranteed, you may need to use respirators with an air supply.

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Safety rules - Ecology and the environment Soil, air, and water quality is important for all industries and life in general. When legislation does not yet rule the treatment of some of the substances that advanced technology requires, sound judgment should govern the use and disposal of products of a chemical and petrochemical nature. Familiarize yourself with the relative legislation applicable to your country, and make sure that you understand this legislation. Where no legislation exists, obtain information from suppliers of oils, filters, batteries, fuels, anti-freeze, cleaning agents, etc., with regard to the effect of these substances on man and nature and how to safely store, use, and dispose of these substances.

Helpful hints • Avoid the use of cans or other inappropriate pressurized fuel delivery systems to fill tanks. Such delivery systems may cause considerable spillage. • In general, avoid skin contact with all fuels, oils, acids, solvents, etc. Most of these products contain substances that may be harmful to your health. • Modern oils contain additives. Do not burn contaminated fuels and or waste oils in ordinary heating systems. • Avoid spillage when you drain fluids such as used engine coolant mixtures, engine oil, hydraulic fluid, brake fluid, etc. Do not mix drained brake fluids or fuels with lubricants. Store all drained fluids safely until you can dispose of the fluids in a proper way that complies with all local legislation and available resources. • Do not allow coolant mixtures to get into the soil. Collect and dispose of coolant mixtures properly. • The air-conditioning system contains gases that should not be released into the atmosphere. Consult an air-conditioning specialist or use a special extractor to recharge the system properly. • Repair any leaks or defects in the engine cooling system or hydraulic system immediately. • Do not increase the pressure in a pressurized circuit as this may lead to a component failure. • Protect hoses during welding. Penetrating weld splatter may burn a hole or weaken hoses, allowing the loss of oils, coolant, etc.

Battery recycling Batteries and electric accumulators contain several substances that can have a harmful effect on the environment if the batteries are not properly recycled after use. Improper disposal of batteries can contaminate the soil, groundwater, and waterways. NEW HOLLAND strongly recommends that you return all used batteries to a NEW HOLLAND dealer, who will dispose of the used batteries or recycle the used batteries properly. In some countries, this is a legal requirement.

Mandatory battery recycling NOTE: The following requirements are mandatory in Brazil. Batteries are made of lead plates and a sulfuric acid solution. Because batteries contain heavy metals such as lead, CONAMA Resolution 401/2008 requires you to return all used batteries to the battery dealer when you replace any batteries. Do not dispose of batteries in your household garbage. Points of sale are obliged to: • Accept the return of your used batteries • Store the returned batteries in a suitable location • Send the returned batteries to the battery manufacturer for recycling

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

Throughout this manual and on machine safety signs, you will find the signal words DANGER, WARNING, and CAUTION followed by special instructions. These precautions are intended for the personal safety of you and those working with you. Read and understand all the safety messages in this manual before you operate or service the machine.

DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury. The color associated with DANGER is RED. WARNING indicates a hazardous situation that, if not avoided, could result in death or serious injury. The color associated with WARNING is ORANGE. CAUTION indicates a hazardous situation that, if not avoided, could result in minor or moderate injury. The color associated with CAUTION is YELLOW.

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

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

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Torque - Minimum tightening torques for normal assembly METRIC NON-FLANGED HARDWARE NOM. SIZE

M4 M5 M6 M8

CLASS 8.8 BOLT and CLASS 8 NUT PLATED UNPLATED W/ZnCr

CLASS 10.9 BOLT and CLASS 10 NUT PLATED UNPLATED W/ZnCr

2.2 N·m (19 lb in) 4.5 N·m (40 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.2 N·m (28 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 26 N·m (234 lb in)

M10

37 N·m (27 lb ft)

M12

64 N·m (47 lb ft)

M16 M20 M24

158 N·m (116 lb ft) 319 N·m (235 lb ft) 551 N·m (410 lb ft)

2.9 N·m (26 lb in) 5.9 N·m (52 lb in) 10 N·m (89 lb in) 25 N·m (217 lb in) 49 N·m (36 lb ft) 85 N·m (63 lb ft) 210 N·m (155 lb ft) 425 N·m (313 lb ft) 735 N·m (500 lb ft)

52 N·m (38 lb ft) 91 N·m (67 lb ft) 225 N·m (166 lb ft) 440 N·m (325 lb ft) 762 N·m (560 lb ft)

4.2 N·m (37 lb in) 8.5 N·m (75 lb in) 15 N·m (128 lb in) 35 N·m (311 lb in) 70 N·m (51 lb ft) 121 N·m (90 lb ft) 301 N·m (222 lb ft) 587 N·m (433 lb ft) 1016 N·m (750 lb ft)

LOCKNUT CL.8 W/CL8.8 BOLT

2 N·m (18 lb in) 4 N·m (36 lb in) 6.8 N·m (60 lb in) 17 N·m (151 lb in) 33 N·m (25 lb ft) 58 N·m (43 lb ft) 143 N·m (106 lb ft) 290 N·m (214 lb ft) 501 N·m (370 lb ft)

LOCKNUT CL.10 W/CL10.9 BOLT 2.9 N·m (26 lb in) 5.8 N·m (51 lb in) 10 N·m (89 lb in) 24 N·m (212 lb in) 48 N·m (35 lb ft) 83 N·m (61 lb ft) 205 N·m (151 lb ft) 400 N·m (295 lb ft) 693 N·m (510 lb ft)

NOTE: M4 through M8 hardware torque specifications are shown in pound-inches. M10 through M24 hardware torque specifications are shown in pound-feet.

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INTRODUCTION

METRIC FLANGED HARDWARE NOM. SIZE

CLASS 8.8 BOLT and CLASS 8 NUT PLATED W/ZnCr

UNPLATED M4 M5 M6 M8

2.4 N·m (21 lb in) 4.9 N·m (43 lb in) 8.3 N·m (73 lb in) 20 N·m (179 lb in)

M10

40 N·m (30 lb ft)

M12

70 N·m (52 lb ft)

M16 M20 M24

174 N·m (128 lb ft) 350 N·m (259 lb ft) 607 N·m (447 lb ft)

3.2 N·m (28 lb in) 6.5 N·m (58 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in) 54 N·m (40 lb ft) 93 N·m (69 lb ft) 231 N·m (171 lb ft) 467 N·m (345 lb ft) 809 N·m (597 lb ft)

CLASS 10.9 BOLT and CLASS 10 NUT

UNPLATED 3.5 N·m (31 lb in) 7.0 N·m (62 lb in) 12 N·m (105 lb in) 29 N·m (257 lb in) 57 N·m (42 lb ft) 100 N·m (74 lb ft) 248 N·m (183 lb ft) 484 N·m (357 lb ft) 838 N·m (618 lb ft)

4.6 N·m (41 lb in) 9.4 N·m (83 lb in) 16 N·m (141 lb in) 39 N·m (343 lb in) 77 N·m (56 lb ft) 134 N·m (98 lb ft) 331 N·m (244 lb ft) 645 N·m (476 lb ft) 1118 N·m (824 lb ft)

Metric Hex head and carriage bolts, classes 5.6 and up

1. Manufacturer's Identification 2. Property Class

Metric Hex nuts and locknuts, classes 05 and up

20083681

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LOCKNUT CL.10 W/CL10.9 BOLT

2.2 N·m (19 lb in) 4.4 N·m (39 lb in) 7.5 N·m (66 lb in) 18 N·m (163 lb in)

3.1 N·m (27 lb in) 6.4 N·m (57 lb in) 11 N·m (96 lb in) 27 N·m (240 lb in)

PLATED W/ZnCr

IDENTIFICATION

20083680

LOCKNUT CL.8 W/CL8.8 BOLT

37 N·m (27 lb ft) 53 N·m (39 lb ft) 63 N·m (47 lb ft) 91 N·m (67 lb ft) 158 N·m (116 lb ft) 318 N·m (235 lb ft) 552 N·m (407 lb ft)

226 N·m (167 lb ft) 440 N·m (325 lb ft)

INTRODUCTION

1. Manufacturer's Identification 2. Property Class 3. Clock Marking of Property Class and Manufacturer's Identification (Optional), i.e. marks 60 ° apart indicate Class 10 properties, and marks 120 ° apart indicate Class 8.

INCH NON-FLANGED HARDWARE NOMINAL SIZE

SAE GRADE 5 BOLT and NUT UNPLATED or PLATED SILVER

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

SAE GRADE 8 BOLT and NUT

UNPLATED PLATED W/ZnCr or PLATED GOLD SILVER

LOCKNUT GrB W/ Gr5 BOLT

LOCKNUT GrC W/ Gr8 BOLT

PLATED W/ZnCr GOLD

12 N·m 16 N·m 8 N·m (71 lb 11 N·m (97 lb (106 lb in) (142 lb in) in) in) 17 N·m 23 N·m 24 N·m 32 N·m (150 lb in) (204 lb in) (212 lb in) (283 lb in) 40 N·m 43 N·m (31 lb 57 N·m (42 lb 30 N·m (22 lb (30 lb ft) ft) ft) ft) 65 N·m 48 N·m (36 lb 68 N·m (50 lb 91 N·m (67 lb (48 lb ft) ft) ft) ft) 98 N·m 104 N·m 139 N·m 74 N·m (54 lb (73 lb ft) (77 lb ft) (103 lb ft) ft) 107 N·m 142 N·m 150 N·m 201 N·m (79 lb ft) (105 lb ft) (111 lb ft) (148 lb ft) 147 N·m 196 N·m 208 N·m 277 N·m (108 lb ft) (145 lb ft) (153 lb ft) (204 lb ft) 261 N·m 348 N·m 369 N·m 491 N·m (193 lb ft) (257 lb ft) (272 lb ft) (362 lb ft) 420 N·m 561 N·m 594 N·m 791 N·m (310 lb ft) (413 lb ft) (438 lb ft) (584 lb ft) 630 N·m 841 N·m 890 N·m 1187 N·m (465 lb ft) (620 lb ft) (656 lb ft) (875 lb ft)

12.2 N·m (109 lb in) 17.5 N·m (155 lb 25 N·m (220 lb in) in)

8.5 N·m (75 lb in)

31 N·m (23 lb ft) 44 N·m (33 lb ft) 50 N·m (37 lb ft) 71 N·m (53 lb ft) 108 N·m (80 lb ft) 156 N·m (115 lb 111 N·m (82 lb ft) ft) 153 N·m (113 lb 215 N·m (159 lb ft) ft) 271 N·m (200 lb 383 N·m (282 lb ft) ft) 437 N·m (323 lb 617 N·m (455 lb ft) ft) 654 N·m (483 lb 924 N·m (681 lb ft) ft) 76 N·m (56 lb ft)

NOTE: For Imperial Units, 1/4 in and 5/16 in hardware torque specifications are shown in pound-inches. 3/8 in through 1 in hardware torque specifications are shown in pound-feet.

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INTRODUCTION

INCH FLANGED HARDWARE NOMSAE GRADE 5 BOLT and SAE GRADE 8 BOLT and INAL NUT NUT SIZE UNPLATED PLATED UNPLATED PLATED or PLATED W/ZnCr or PLATED W/ZnCr SILVER GOLD SILVER GOLD 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1

9 N·m (80 lb in) 19 N·m (168 lb in) 33 N·m (25 lb ft) 53 N·m (39 lb ft) 81 N·m (60 lb ft) 117 N·m (86 lb ft) 162 N·m (119 lb ft) 287 N·m (212 lb ft) 462 N·m (341 lb ft) 693 N·m (512 lb ft)

LOCKNUT GrF W/ Gr5 BOLT

12 N·m (106 lb 13 N·m (115 lb 17 N·m (150 lb 8 N·m (71 lb in) in) in) in) 25 N·m (221 lb 26 N·m (230 lb 35 N·m (310 lb 17 N·m (150 lb in) in) in) in) 44 N·m (33 lb 47 N·m (35 lb 63 N·m (46 lb 30 N·m (22 lb ft) ft) ft) ft) 71 N·m (52 lb 75 N·m (55 lb 100 N·m (74 lb 48 N·m (35 lb ft) ft) ft) ft) 153 N·m 108 N·m (80 lb 115 N·m (85 lb 74 N·m (55 lb ft) (113 lb ft) ft) ft) 156 N·m 165 N·m 221 N·m 106 N·m (78 lb ft) (115 lb ft) (122 lb ft) (163 lb ft) 216 N·m 228 N·m 304 N·m 147 N·m (108 lb (159 lb ft) (168 lb ft) (225 lb ft) ft) 383 N·m 405 N·m 541 N·m 261 N·m (193 lb (282 lb ft) (299 lb ft) (399 lb ft) ft) 617 N·m 653 N·m 871 N·m 421 N·m (311 lb (455 lb ft) (482 lb ft) (642 lb ft) ft) 925 N·m 979 N·m 1305 N·m 631 N·m (465 lb (682 lb ft) (722 lb ft) (963 lb ft) ft)

LOCKNUT GrG W/ Gr8 BOLT

12 N·m (106 lb in) 24 N·m (212 lb in) 43 N·m (32 lb ft) 68 N·m (50 lb ft) 104 N·m (77 lb ft) 157 N·m (116 lb ft) 207 N·m (153 lb ft) 369 N·m (272 lb ft) 594 N·m (438 lb ft) 890 N·m (656 lb ft)

IDENTIFICATION Inch Bolts and free-spinning nuts

20083682

Grade Marking Examples 1 2 3

Grade 2 - No Marks Grade 5 - Three Marks Grade 8 - Five Marks

SAE Grade Identification 4 Grade 2 Nut - No Marks 5 Grade 5 Nut - Marks 120 ° Apart 6 Grade 8 Nut - Marks 60 ° Apart

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INTRODUCTION

Inch Lock Nuts, All Metal (Three optional methods)

20090268

Grade Identification Grade Grade A Grade B Grade C

Corner Marking Method (1) No Notches One Circumferential Notch Two Circumferential Notches

Flats Marking Method (2) No Mark Letter B Letter C

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Clock Marking Method (3) No Marks Three Marks Six Marks

INTRODUCTION

Basic instructions — Shop and assembly Shimming For each adjustment operation, select adjusting shims and measure the adjusting shims individually using a micrometer, then add up the recorded values. Do not rely on measuring the entire shimming set, which may be incorrect, or the rated value shown on each shim.

Rotating shaft seals For correct rotating shaft seal installation, proceed as follows: 1. Before assembly, allow the seal to soak in the oil it will be sealing for at least thirty minutes. 2. Thoroughly clean the shaft and check that the working surface on the shaft is not damaged. 3. Position the sealing lip facing the fluid. NOTE: With hydrodynamic lips, take into consideration the shaft rotation direction and position the grooves so that they will move the fluid towards the inner side of the seal. 4. Coat the sealing lip with a thin layer of lubricant (use oil rather than grease). Fill the gap between the sealing lip and the dust lip on double lip seals with grease. 5. Insert the seal in its seat and press down using a flat punch or seal installation tool. Do not tap the seal with a hammer or mallet. 6. While you insert the seal, check that the seal is perpendicular to the seat. When the seal settles, make sure that the seal makes contact with the thrust element, if required. 7. To prevent damage to the seal lip on the shaft, position a protective guard during installation operations.

O-ring seals Lubricate the O-ring seals before you insert them in the seats. This will prevent the O-ring seals from overturning and twisting, which would jeopardize sealing efficiency.

Sealing compounds Apply a sealing compound on the mating surfaces when specified by the procedure. Before you apply the sealing compound, prepare the surfaces as directed by the product container.

Spare parts Only use CNH Original Parts or NEW HOLLAND Original Parts. Only genuine spare parts guarantee the same quality, duration, and safety as original parts, as they are the same parts that are assembled during standard production. Only CNH Original Parts or NEW HOLLAND Original Parts can offer this guarantee. When ordering spare parts, always provide the following information: • Machine model (commercial name) and Product Identification Number (PIN) • Part number of the ordered part, which can be found in the parts catalog

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INTRODUCTION

Protecting the electronic and/or electrical systems during charging and welding To avoid damage to the electronic and/or electrical systems, always observe the following practices: 1. Never make or break any of the charging circuit connections when the engine is running, including the battery connections. 2. Never short any of the charging components to ground. 3. Always disconnect the ground cable from the battery before arc welding on the machine or on any machine attachment. • Position the welder ground clamp as close to the welding area as possible. • If you weld in close proximity to a computer module, then you should remove the module from the machine. • Never allow welding cables to lie on, near, or across any electrical wiring or electronic component while you weld. 4. Always disconnect the negative cable from the battery when charging the battery in the machine with a battery charger. NOTICE: If you must weld on the unit, you must disconnect the battery ground cable from the machine battery. The electronic monitoring system and charging system will be damaged if this is not done. 5. Remove the battery ground cable. Reconnect the cable when you complete welding.

WARNING Battery acid causes burns. Batteries contain sulfuric acid. Avoid contact with skin, eyes or clothing. Antidote (external): Flush with water. Antidote (eyes): flush with water for 15 minutes and seek medical attention immediately. Antidote (internal): Drink large quantities of water or milk. Do not induce vomiting. Seek medical attention immediately. Failure to comply could result in death or serious injury. W0111A

Special tools The special tools that NEW HOLLAND suggests and illustrate in this manual have been specifically researched and designed for use with NEW HOLLAND machines. The special tools are essential for reliable repair operations. The special tools are accurately built and rigorously tested to offer efficient and long-lasting operation. By using these tools, repair personnel will benefit from: • Operating in optimal technical conditions • Obtaining the best results • Saving time and effort • Working in safe conditions

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INTRODUCTION

Torque — Standard torque data for hydraulics Installation of adjustable fittings in straight thread O-ring bosses 1. Lubricate the O-ring by coating it with a light oil or petroleum. Install the O-ring in the groove adjacent to the metal backup washer which is assembled at the extreme end of the groove (4). 2. Install the fitting into the SAE straight thread boss until the metal backup washer contacts the face of the boss (5). NOTE: Do not over tighten and distort the metal backup washer.

23085659

3. Position the fitting by turning out (counterclockwise) up to a maximum of one turn. Holding the pad of the fitting with a wrench, tighten the locknut and washer against the face of the boss (6).

Standard torque data for hydraulic tubes and fittings Tube nuts for 37° flared fittings

Size

Tubing OD

Thread size

Torque

O-ring boss plugs adjustable fitting locknuts, swivel JIC37° seats Torque

4 5 6 8 10 12 14 16 20 24 32

6.4 mm (1/4 in) 7.9 mm (5/16 in) 9.5 mm (3/8 in) 12.7 mm (1/2 in) 15.9 mm (5/8 in) 19.1 mm (3/4 in) 22.2 mm (7/8 in) 25.4 mm (1 in) 31.8 mm (1-1/4 in) 38.1 mm (1-1/2 in) 50.8 mm (2 in)

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

12 - 16 N·m (9 - 12 lb ft) 16 - 20 N·m (12 - 15 lb ft) 29 - 33 N·m (21 - 24 lb ft) 47 - 54 N·m (35 - 40 lb ft) 72 - 79 N·m (53 - 58 lb ft) 104 - 111 N·m (77 - 82 lb ft) 122 - 136 N·m (90 - 100 lb ft) 149 - 163 N·m (110 - 120 lb ft) 190 - 204 N·m (140 - 150 lb ft) 217 - 237 N·m (160 - 175 lb ft) 305 - 325 N·m (225 - 240 lb ft)

8 - 14 N·m (6 - 10 lb ft) 14 - 20 N·m (10 - 15 lb ft) 20 - 27 N·m (15 - 20 lb ft) 34 - 41 N·m (25 - 30 lb ft) 47 - 54 N·m (35 - 40 lb ft) 81 - 95 N·m (60 - 70 lb ft) 95 - 109 N·m (70 - 80 lb ft) 108 - 122 N·m (80 - 90 lb ft) 129 - 158 N·m (95 - 115 lb ft) 163 - 190 N·m (120 - 140 lb ft) 339 - 407 N·m (250 - 300 lb ft)

These torques are not recommended for tubes of 12.7 mm (1/2 in) OD and larger with wall thickness of 0.889 mm (0.035 in) or less. The torque is specified for 0.889 mm (0.035 in) wall tubes on each application individually. Before installing and torquing 37 ° flared fittings, clean the face of the flare and threads with a clean solvent or Loctite cleaner and apply hydraulic sealant LOCTITE® 569™ to the 37 ° flare and the threads. Install fitting and torque to specified torque, loosen fitting and retorque to specifications.

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INTRODUCTION

Pipe thread fitting torque Before installing and tightening pipe fittings, clean the threads with a clean solvent or Loctite cleaner and apply sealant LOCTITE® 567™ PST PIPE SEALANT for all fittings including stainless steel or LOCTITE® 565™ PST for most metal fittings. For high filtration/zero contamination systems use LOCTITE® 545™.

Torque (maximum) 13 N·m (10 lb ft) 16 N·m (12 lb ft) 22 N·m (16 lb ft) 41 N·m (30 lb ft) 54 N·m (40 lb ft)

Thread size 1/8-27 1/4-18 3/8-18 1/2-14 3/4-14

Installation of ORFS (O-Ring Flat Seal fittings) When installing ORFS fittings thoroughly clean both flat surfaces of the fittings (1) and lubricate the O-ring (2) with light oil. Make sure both surfaces are aligned properly. Torque the fitting to specified torque listed throughout the repair manual. NOTICE: If the fitting surfaces are not properly cleaned, the O-ring will not seal properly. If the fitting surfaces are not properly aligned, the fittings may be damaged and will not seal properly. NOTICE: Always use genuine factory replacement oils and filters to ensure proper lubrication and filtration of engine and hydraulic system oils. The use of proper oils, grease, and keeping the hydraulic system clean will extend machine and component life.

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50011183

INTRODUCTION

Capacities Hydraulic and Cooling System With Platform TL60E TL75E, TL85E, and TL95E With cab TL60E TL75E, TL85E, and TL95E Air Conditioning System Refrigerant Compressor oil Windscreen washer reservoir Fuel reservoir Standard Auxil. Engine Engine oil without filter TL60E TL75E, TL85E, and TL95E Engine oil with filter TL60E

Amount (L)

Recommended fluid

Specification NEW HOLLAND

Corresponding international specification

12 13,50

50% water and 50% NEW HOLLAND AMBRA AGRIFLU

NH 90DA

NH 330G SAE 15W-40) NH 324G (SAE 10W-30)

M2C-906A API CG-4 ACEA A3/B4-04

NH 300H

M2C-906A API CI-4/ CH-4 ACEA E5/02, E7/04 CUMMINS CES 20078

NEW HOLLAND AMBRA BRAKE LHM

NH 610A

ISO 7308

NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL

NH 410B

SAE 10W-30 API GL4 ISO 32/46

NEW HOLLAND AMBRA GR 75 MD

NH 720A

NLGI 2

14 14,25 1,5 kg CNH REFRIGERANT HFC-134A 270 - 300 cm³ SP-15 Water and AREXONS DP1 2 liquid 128 55

7,6 10,5 8,6

TL75E, TL85E, and TL95E

11,8

Break circuit

0,4

Hydrostatic steering circuit Front axle Cage TL60E and TL75E TL85E and TL95E Final reducers (each) TL60E and TL75E TL85E and TL95E Rear axle Rear axle (brake and final reducers conical group), transmission, hydraulic system, Power Take-Off (PTO), and hydrostatic steering: TL60E and TL75E TL85E and TL95E With synchronized inverter TL60E, TL75E, TL85E, and TL95E Front wheel hubs Grease fitings

2,0

Diesel oil or Biodiesel B (B5) - Brazil

NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15W-40 or NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 10W-30

4,5 7,0 0,8 1,25

52,8 55 55 — —

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CONSUMABLES INDEX Consumable Loctite® 569™ Loctite® 567™ PST Pipe Sealant Loctite® 565™ PST Loctite® 545™ NEW HOLLAND AMBRA AGRIFLU CNH Refrigerant HFC-134a NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 15W-40 NEW HOLLAND AMBRA MASTERGOLD™ HSP ENGINE OIL SAE 10W-30 NEW HOLLAND AMBRA BRAKE LHM NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL NEW HOLLAND AMBRA GR 75 MD

Reference

PAGE

Torque — Standard torque data for hydraulics Torque — Standard torque data for hydraulics

25 26

Torque — Standard torque data for hydraulics Torque — Standard torque data for hydraulics Capacities

26 26 27

Capacities Capacities

27 27

Capacities

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SERVICE MANUAL Engine TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015

Contents Engine - 10

[10.001] Engine and crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.1 [10.106] Valve drive and gears . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.2 [10.101] Cylinder heads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3 [10.105] Connecting rods and pistons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4 [10.103] Crankshaft and flywheel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5 [10.216] Fuel tanks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6 [10.218] Fuel injection system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7 [10.254] Intake and exhaust manifolds and muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.8 [10.400] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.9

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CONSUMABLES INDEX Consumable Loctite® Loctite®

Reference Engine - Install Engine - Install

PAGE 10.1 / 15 10.1 / 15

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Engine - 10 Engine and crankcase - 001

TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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10.1 [10.001] / 1

Contents Engine - 10 Engine and crankcase - 001

TECHNICAL DATA Engine General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Engine Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

(*) See content for specific models 47835583 21/10/2015

10.1 [10.001] / 2

CONSUMABLES INDEX Consumable Loctite® Loctite®

Reference Engine - Install Engine - Install

PAGE 10.1 / 15 10.1 / 15

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10.1 [10.001] / 3

Engine - Engine and crankcase

Engine - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

TL60E 3

Number of cylinders Loop Injection Piston diameter Piston stroke Injection Sequence Engine speeds Idle speed

1–2–3

TL85E 4 Diesel, 4 stroke Direct 104 mm 115 mm 1–3–4–2

TL95E

730 820 RPM

Maximum rotation Rated speed Total cylinder capacity Compression ratio Maximum engine power (SAE J1995) Maximum engine torque at 1400 RPM (SAE J1995) Number of main bearing housings Sump Maximum working inclination - Transversal Maximum working inclination - Longitudinal Rev counter Acionamento Gauge calibrated for engine at Pad Cylinder hole diameter Grinding External diameter oversize Diameter of housing for the main bushings covers Diameter of housings for control shaft bushings: Front Middle Rear Diameter of tappet housings Tappet oversize Main bearing seat bore diameter Engine fan type Engine fan diameter Number of paddles

TL75E

650 730 725 750 RPM 830 RPM 775 RPM 2600 2700 2605 2700 RPM 2800 RPM 2655 RPM 2500 RPM 2400 RPM 2931 cm³ 3908 cm³ 17,5:1 75.0 kW 41.0 kW 56.0 kW ( 63.0 kW ( (55.7 Hp)@ 76.1 Hp)@ 85.7 Hp)@ (102.0 Hp)@ 2400 RPM 2400 RPM 2400 RPM 2500 RPM 205 N·m 280 N·m 325 N·m 380 N·m 5 4 Cast iron 35 ° 30 ° Incorporated in control panel Originated from the distribution shaft gear 1800 RPM Cast iron monoblock, incorporates housings for distribution shaft / tappet fittings 106.850 - 106.900 mm 0.400 - 0.800 mm 0.200 mm 84.200 - 84.230 mm 54.780 - 54.802 mm 54.280 - 54.305 mm 53.780 - 53.805 mm 15.000 - 15.018 mm 0.100 mm - 0.200 mm - 0.300 mm 84.200 - 84.230 mm Fixed 450.0 mm 448.0 mm (17.6 in) (17.7 in) 4 10

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Engine - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Drain the coolant from the engine. Consult the procedures in Radiator - Drain fluid (10.400). 1. Disconnect the battery negative (-) cable (1).

CUIL13TRO0194AA

CUIL13TR00802AA

2. Loosen the clamps and the hose (3) and lift the tube (2) so that the oil does not drain out. The hose (1) allows this movement. NOTICE: Protect the end of the hose (1) against the entry of impurities.

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Engine - Engine and crankcase

3. Remove the tool box and the respective support (1). 4. Remove the front ballasts. Consult the procedures in Front ballast - Remove (39.140). 5. Remove the engine side shield. Consult the procedures in Side shield - Remove (90.102). 6. Remove the engine hood. Consult the procedures in Hood - Remove (90.100).

LAIL11TL1104A0A

CUIL13TR00475AA

CUIL13TR00333AA

CUIL13TR00810AA

7. Disconnect the tubes (1) and (2) from the hydraulic pump outlet. NOTICE: Protect the end of the hose against the entry of impurities. 8. Drain the coolant from the engine. Consult the procedures in Radiator - Drain fluid (10.400).

9. Disconnect the fuel line (2) and the electrical cable (1) from the pre-heating glow plug. 10. Disconnect the injector fuel return pipe and the connection pipe from the tank to the decanter filter. 11. Remove the complete fuel filter support. 12. Disconnect the support bracket from the flexible brake lines.

13. Disconnect the electric connection (1) from the engine coolant sensor. 14. Disconnect the electric connections located between the cab and the engine on the left-hand side.

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15. Disconnect the cable of the engine oil pressure sensor (1). Disconnect the rev counter control and remove the fixing support.

CUIL13TR00783AA

LAIL11TL1118A0A

CUIL13TR00842AA

16. Remove the fastening clamp (1) from the pipes to the steering cylinder.

17. Disconnect the flexible oil pressure and return lines (1) and (2) to the steering cylinders. NOTE: Identify the hoses before disconnecting them for easy installation. 18. Remove the Auxiliary Front Wheel Drive (AFWD) drive shaft. Consult the procedures in Drive shaft Remove (23.314).

19. Disconnect the rigid oil pressure line (1) to the transfer box control. 20. Remove the exhaust system. Consult the procedures in Exhaust muffler - Remove (10.254).

CUIL13TR00774AA

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21. Lift the front of the platform or cab floor mat.

LAIL11TL1126A0A

LAIL11TL1127A0A

LAIL11TL1128A0A

CUIL13TR00743AA

22. Remove the covers (1) to access the upper screws securing the engine.

23. Disconnect the control pedal throttle cable.

24. Loosen the front two bolts (1) securing the cab to the relative supports. NOTE: Repeat the procedure on the other side of the machine.

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Engine - Engine and crankcase

25. Lift the front of the cab approximately 6.0 cm (2.4 in).

LAIL11TL1130A0A

LAIL11TL1131A0A

LAIL11TL1132A0A

LAIL11TL1133A0A

26. Loosen the two nuts and the top two bolts securing the engine to the transmission. Access is by opening the cover removed earlier on the floor, under the brake and clutch pedals.

27. Remove the four lower bolts (1) securing the engine to the transmission.

28. Place the tool (trolley) under the tractor and put two wedges on the front shaft to prevent swaying. 29. Place a wooden shim (1) on the contact points between the trestles and the tractor.

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Engine - Engine and crankcase

30. Place a fixed trestle (1) under the draw bar support and pull the handbrake.

LAIL11TL1134A0A

LAIL11TL1135A0A

LAIL11TL1136A0A

LAIL11TL1137A0A

31. Remove the support clamp (1) from the cab heating lines. 32. Identify and disconnect the hoses for flow and return of fluid to the heating system.

33. Loosen the last four fixing bolts from the engine to the transmission. 34. Disconnect the three electric connectors (1) from the relative support. 35. Separate the engine from the transmission.

36. Remove the spacer (1) installed between the engine and the transmission.

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37. Place a fixed trestle (1) under the counterweight cradle and block the front wheels with wooden wedges (2).

LAIL11TL1138A0A

LAIL11TL1139A0A

LAIL11TL1140A0A

CUIL13TR00782AA

38. Insert tool no. 380000292 (1) into the clutch disc. Loosen the six fixing bolts from the clutch to the engine flywheel and completely remove the clutch assembly.

39. Remove the screw (2) securing the tubing to the engine and remove the tubing of the low-pressure hydraulic circuit. 40. Hitch the engine to the winch with the chain, fixing it to the engine supports intended for this purpose.

41. Remove the four bolts (1) and remove the pump (2). 42. Disconnect all electric connectors and remove the entire cable assembly.

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Engine - Engine and crankcase

43. Loosen the clamp and disconnect the intake manifold hose (1).

LAIL11TL1142A0A

LAIL11TL1144A0A

LAIL11TL1145A0A

LAIL11TL1147A0A

44. Remove the bracket and disconnect the tube (1) linking the engine to the radiator.

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

46. Lift the engine slightly and position the mobile trestle (1) under the front axle support.

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Engine - Engine and crankcase

47. Remove the clamp and disconnect the lower radiator hose (1). 48. Remove the four bolts (2) securing the engine and remove the engine and axle support.

LAIL11TL1148A0A

LAIL11TT0008A0A

49. Carefully detach the engine from the front axle and mount it on the engine stand 380000154.

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Engine - Engine and crankcase

Engine - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

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

1. Fasten the three hooks to the three eye bolts, propping the engine with an adjustable chain. Lift the engine from the platform and position it on the front of the front axle support. Join the two groups by fastening them with the four fixing bolts. 2. Move the mobile trestle from the front axle to the engine sump, inserting a molded piece of wood between the trestle and the sump. 3. Also join the lower flexible pipe from the radiator with the water pump inlet, through a rubber hose fasten all the pipes with metal, adjustable clamps. LAIL11TL1154A0A

CUIL13TR00696AA

4. Connect the lower radiator hose to the cooling pump and fasten both ends with adjustable hose clamps. 5. Reassemble the lift pump, installing the bolts (1) 6. Remove the engine chain.

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Engine - Engine and crankcase

7. Install the hose (1) to the intake manifold. Install and tighten the respective clamps. 8. Connect all the disconnected electrical connections: heater glow plug, engine temperature sensor, air filter restriction sensor, front axle carrier mass (negative), injector pump solenoid cable. alternator cables, engine oil pressure sensor, starter motor connection. Attach the wiring harnesses of the electrical cables with appropriate plastic straps. If necessary, see the electrical diagrams in section 55.

LAIL11TL1142A0A

LAIL11TL1139A0A

LAIL11TL1138A0A

9. Install the clutch using tool 380000292 (1). Lock the clutch on the engine flywheel fastening it with the six bolts (2). 10. Install the oil pressure tube to the control valve of the Auxiliary Front Wheel Drive (AFWD). 11. Clean the clutch housing spacer and contact surface. Clean the old sealing paste from the engine surface. 12. Smear sealing paste LOCTITEÂŽ on the engine and spacer contact surfaces. Assemble the spacer to the studs threaded on the engine. 13. Smear sealing paste LOCTITEÂŽ on the clutch housing surfaces. 14. Remove the fixed trestle (1) under the counterweight holder. 15. Remove the wooden wedges (2) from the lower part of the front wheels. 16. Fasten the engine to the adequate eye bolts with the adjustable chain. 17. Place wooden wedges under the rear wheels, make sure the hand brake is pulled and that all fixed and mobile trestles are well fastened. 18. This phase requires two or three workers. Place the front axle engine group close to the clutch housing by pushing the front wheels and following with the winch. Pay attention to the oil suction rigid pipes and the transfer box pressure pipe. In addition, check if the cables or wires are not smashed between the two bodies. After that move the drive shaft by turning the cooling fan to allow for the second axle to hitch. Lock the two groups with some bolts.

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Engine - Engine and crankcase

19. Unhook the engine chain. Connect the two hooked cables still on the cab handrail to the winch hook. Lift the front of the cab 6 cm again. 20. Tighten well all the clutch housing motor fixing bolts. 21. Tighten the brake line support clamp on the right-hand side of the engine. Lower the winch and disconnect the handrail cables. 22. Lower the trestles from the lower part of the engine sump and the clutch housing. Remove the tractor splitter kit and the trestle from under the draw bar support. Lock the cab, fastening it with two front bolts. 23. Connect the flexible pipe to the injector return pipe.

LAIL11TL1130A0A

CUIL13TR00693AA

CUIL13TR00843AA

LAIL11TL1135A0A

24. Reassemble the fuel filter support, fastening it to the engine. Connect the two semi-rigid pipes to the support. 25. Reassemble the rigid oil suction pipes (1), (2) and (3) to the pumps and fasten the rubber hose (4) with clamps.

26. Install the electrical connection of the front part of the tractor to electrical sockets (1) and (2) located above the hydrostatic steering unit.

27. Reassemble the cab heating pipe gasket in the engine spacer in the clutch housing. Fasten with the clamp (1).

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Engine - Engine and crankcase

28. Connect steering hydraulic hoses (1) and (2). 29. Install the muffler on the exhaust manifold. Consult the procedures in Exhaust muffler - Remove (10.254).

CUIL13TR00842AA

CUIL13TR00846AA

LAIL11TL1120A0A

30. Connect the upper (1) and lower (3) hose of the radiator and the dust ejector system hose (2) (if equipped).

31. Assemble the front wheel drive prop shaft with its respective latch rings and assemble the guard plate tightening the front, central, and lower bolts. 32. Reassemble the throttle cable on the pedal. If necessary, adjust the cable on the lever installed in the injection pump.

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Engine - Engine and crankcase

33. Connect the tie rod (1) (platform tractors) or the cable (for cab tractors) to the gear pedal. Refer to the Operatorâ&#x20AC;&#x2122;s Manual for adjusting the pedal height.

CUIL13TR00847AA

LAIL11TL1127A0A

CUIL13TR00322AA

CUIL13TR00323AA

34. Reinstall the plastic covers (1) on the openings installed on the cab floor. Reinstall the floor mat. 35. Reinstall the side panels of the instrument panel.

36. Install the engine side shield (2) and secure it with the upper bolt (1).

37. Install the lower bolt (1).

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Engine - Engine and crankcase

38. Install the hood, securing it on the support with the two articulation pins (1) and (3). 39. Install the two gas hood cylinders (2).

CUIL13TR00350AA

CUIL13TR00470AA

40. Reassemble the front weights (2) and fasten them with the vertical pin (1). 41. Reassemble the tool holder box support clamp, then fasten the box to the clamp.

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Engine - Engine and crankcase

Engine - Compression test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

WARNING Chemical hazard! When handling fuel, lubricants, and other service chemicals, follow the manufacturer's instructions. Wear Personal Protective Equipment (PPE) as instructed. Do not smoke or use open flame. Collect fluids in proper containers. Obey all local and environmental regulations when disposing of chemicals. Failure to comply could result in death or serious injury. W0371A

Compression is a measurement that can indicate the state of the cylinder sealing components (rings and valves). Even compression in the different cylinders ensures regular operation of the engine. This is because each cylinder injects the same amount of fuel with each stroke. Low compression reduces engine performance and does not allow all of the fuel to burn. This is because there is not enough air for perfect combustion. As a result, the engine consumes more fuel and releases white smoke through the exhaust. Compression depends on the engine temperature. Only measure compression when the engine is at operating temperature. Compression values will be lower when the engine is cold and higher when the engine is hot.

Test procedures 1. Make sure that the battery is fully charged. 2. Start the engine. Keep the engine running until the temperature of the liquid coolant stabilizes. Observe the machine's instrument cluster. 3. Turn the engine OFF. Remove the key from the key switch 4. Remove the injector and the seat washer from the first cylinder. 5. Clean the internal diameter of the injector. 6. Disconnect the coil of the injector pump. 7. Turn the engine to expel any loose particles. 8. Install the dummy injector nozzle 380000617 in the injector site. Use a new seat washer and the mounting bolts of the injector. 9. Connect the compression meter 380000303 and the hose to the adapter of the dummy injector.

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Engine - Engine and crankcase

10. Start the engine (starter motor only) and note the meter reading. Repeat the procedure for all the engine cylinders. Interpreting the verified compression values • All cylinder compressions must be uniform, or the difference should be within 1.7 bar (24.65 psi) of each other. • A compression difference equal to or greater than 1.7 bar (24.65 psi) for the other cylinders indicates a leak in the head gasket, in the piston rings, or in the valves. • A compression difference equal to or less than 1.7 bar (24.65 psi) for the other cylinders indicates excess carbon deposits on the piston and on the head. • A low even compression in two adjacent cylinders indicates a cylinder head gasket leak. Check this item before condemning the rings or valves.

Rework instructions After performing the tests, perform the lubricant oil consumption test on the engine: • If the oil consumption is below 0.4% no service repair action should be taken. • If oil consumption is diagnosed the engine should be repaired.

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Index Engine - 10 Engine and crankcase - 001

(*)

Engine - Compression test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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models

Engine - 10 Valve drive and gears - 106

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Contents Engine - 10 Valve drive and gears - 106

TECHNICAL DATA Valve drive and gears General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rocker arm General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Camshaft Tappets - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Rocker arm Adjust â&#x20AC;&#x201C; Clearance between the valves and rockers (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

(*) See content for specific models 47835583 21/10/2015

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Engine - Valve drive and gears

Valve drive and gears - General specification TL60E TL75E TL85E TL95E With overhead valves controlled by cams, rods, and rocker arms through the distribution control shaft located on the base and controlled by the crankshaft through helical gears.

Distribution Aspiration Start: End: Unloading Start: End: Play between the rocker arms and valves to control the valve opening and closing diagram Roll diameter Play between distribution gear teeth Internal diameter of distribution gear bushes (installed and finished in the seat) Diameter of transmission gear bushing seat Play between bushing seat and relative bushes Maximum acceptable play from wear Interference between the bush and seat on transmission gear External diameter of bushings on the control shaft: Front Middle Rear Interference between the bushes (control shaft) and the housings in the block External diameter of seats on the control shaft: Front Middle Rear Internal diameter of the bushes on the control shaft (installed and finished in the block): Front Middle Rear Play between the seats and bushes Maximum acceptable play from wear

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12째 before TDC 31째 after BDC 50째 before BDC 16째 0.45 mm 104.000 mm 0.160 mm 37.050 - 37.075 mm 36.975 - 37.000 mm 0.050 - 0.100 mm 0.150 mm 0.063 - 0.140 mm 54.875 - 54.930 mm 54.375 - 54.430 mm 53.875 - 53.930 mm 0.070 - 0.150 mm 50.970 - 51.000 mm 50.470 - 50.500 mm 49.970 - 50.000 mm

51.080 - 51.130 mm 50.580 - 50.630 mm 50.080 - 50.130 mm 0.080 - 0.160 mm 0.200 mm

Engine - Valve drive and gears

Rocker arm - General specification Rocker arm â&#x20AC;&#x201D; valves Rocker arm hole diameters Rocker arm holder shaft diameters Play between shaft and rocker arm holders Maximum acceptable play from wear Characteristics of rocker arm separation spring Rated length of free spring Length of spring with a load of 46 - 52 N (10.34 11.69 lb) Valve play for synchronization (diagram) Valve play for engine operation (cold) Intake valve W gate Path of tappet (from control shaft) Intake valve W gate External diameter of rocker arm bush

TL60E

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TL75E TL85E 18.016 - 18.031 mm 17.982 - 18.000 mm 0.016 - 0.052 mm 0.15 mm 59.5 mm 44 mm 0.45 mm 0.30 mm 0.30 mm 5.955 mm 6.027 mm 21.006 - 21.031 mm

TL95E

Engine - Valve drive and gears

Camshaft Tappets - General specification Tappets Diameter of housing in the block Standard tappet external diameter Play between tappet and block Maximum acceptable play from wear Tappet oversize

TL60E

TL75E TL85E TL95E 15.000 - 15.018 mm 14.950 - 14.970 mm 0.030 - 0.068 mm 0.15 mm 0.100 mm - 0.200 mm - 0.300 mm

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Engine - Valve drive and gears

Rocker arm - Adjust – Clearance between the valves and rockers TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Remove the clamp and disconnect the dust ejector tube. 2. Loosen the two front muffler support fixing bolts. 3. Loosen the fixing nuts from the muffler to the exhaust manifold and remove the muffler.

LAIL11TL1343A0A

LAIL11TL1344A0A

LAIL11TL1345A0A

4. Loosen the four fixing nuts (1) and remove the cover. 5. Remove the flywheel inspection cover (1). 6. Tighten the rockers/valves adjusting bolts (1) to a torque of 25 N·m (18.44 lb ft).

7. Adjust the clearance between the valves and the rockers using: the feeler gauge, the key (1) and the special tool 380000232 (2).

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Index Engine - 10 Valve drive and gears - 106

(*)

Camshaft Tappets - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker arm - Adjust â&#x20AC;&#x201C; Clearance between the valves and rockers (*) . . . . . . . . . . . . . . . . . . . . . . . . .

Rocker arm - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Valve drive and gears - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Cylinder heads - 101

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Contents Engine - 10 Cylinder heads - 101

TECHNICAL DATA Cylinder heads General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Cylinder heads

Cylinder heads - General specification Head Head Original head height Maximum thickness that can be removed Diameter of standard valve guide holes in the head External diameter of standard valve guide Interference between the casings and valve guides on the head Internal diameter of valve guides (installed in the head) Diameter of valve rods Assembly play between the valve rod and valve guides Maximum acceptable play from wear Maximum decentralization of guided valve on the rod measured at 360° from the indicator contact point supported on the valve head contact surface Valve guide oversize Valve housing angle in the head For the intake valve For the exhaust valve Cam lift For the intake valve For the exhaust valve Valve lift For the intake valve For the exhaust valve Valve face angle For the intake valve For the exhaust valve Diameter of valve head For the intake valve For the exhaust valve Distance from the valve face relative to the head plane Maximum acceptable distance Characteristics of springs for intake and exhaust valves: Rated length of free spring Length of spring with valve closed, with a load of 256 284 N (57.551 - 63.846 lb) Length of spring with valve opened, with a load of 502 544 N (112.854 - 122.296 lb) Injector lug in relation to the head plane: BOSCH injector, part no. 4792442, 4800029, 4824170, 99451588 STANADYNE injector, part no. 4802394, 4802391, 99439239 OMAP injector, part no. 4800031 and 4800032 Valve synchronization Inlet opening (before TDC) Inlet closing (after BDC) Exhaust opening (before BDC) Exhaust closing (after TDC)

TL60E TL75E TL85E TL95E With valve seats machined directly on the cast and pressed valve guides (steel) 92 mm 0.500 mm 13.950 - 13.983 mm 13.993 - 14.016 mm

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0.005 - 0.050 mm 8.023 - 8.043 mm 7.985 - 8.000 mm 0.023 - 0.058 mm 0.130 mm 0.030 mm 0.200 mm 55° - 65° 40° - 50° 5.250 mm 5.677 mm 9.31 mm 10.06 mm 60°23'-60°37' 45°23'-45°37' 45.300 - 45.500 mm 37.500 - 37.750 mm 0.700 - 1.000 mm 1.300 mm 44.600 mm 34 mm 23.800 mm

0.300 - 1.100 mm 0.250 - 1.050 mm 0.150 - 0.950 mm 12 ° 31 ° 50 ° 16 °

Index Engine - 10 Cylinder heads - 101 Cylinder heads - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Connecting rods and pistons - 105

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Contents Engine - 10 Connecting rods and pistons - 105

TECHNICAL DATA Connecting rods and pistons General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Connecting rods and pistons

Connecting rods and pistons - General specification Pistons and connecting rods Roll diameter Link conrods Diameter of the link conrod bush seat External diameter of link conrod bush Interference between the bush and link conrod seat Internal diameter of the link conrod bush (measure after installing) Diameter of bush seat on the link conrod Maximum tolerance for parallelism between the two controlled link conrod shafts at 25 mm Maximum difference in link conrod weight in the same engine The figure above shows the location of the fastening holes for auxiliary implements on tractors with platforms. Standard diameter of pistons with 57 mm skirting base measured perpendicularly to the piston pin shaft Maximum play from wear Piston clearance in liner Piston oversize Piston lug from TDC relative to the block Diameter from pin to piston Piston pin housing diameter Play between the pin and piston housings Play between the piston pin and bush

TL60E

TL75E TL85E TL95E 104 mm Cast iron with lubrication orifice 41.846 - 41.884 mm 41.979 - 42.017 mm 0.095 - 0.171 mm 38.004 - 38.014 mm 67.407 - 67.422 mm Âą 0.070 mm 25 g

Light alloy with three rings, two being sealants and one oil scraper

Play in piston ring groove (upper) Maximum acceptable play from wear Maximum difference in piston weight in the same engine Play between the rings and piston channels (vertically): 1st Ring 2nd Ring 3rd Ring Maximum admitted play from wear (between rings and channels) 1st Ring 2nd Ring Play between ring ends (installed) 1st Ring 2nd Ring 3rd Ring Maximum acceptable play between ends from wear

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103.852 - 103.870 mm 0.300 mm 0.174 - 0.212 mm 0.600 mm 0.355 - 0.761 mm 37.983 - 37.990 mm 38.000 - 38.006 mm 0.010 - 0.023 mm 0.014 - 0.031 mm 0.090 0.105 - 0.155 mm 0.122 mm 0.060 mm 20 g 0.090 - 0.122 mm 0.060 - 0.092 mm 0.040 - 0.075 mm

0.500 mm 0.200 mm 0.400 - 0.650 mm 0.300 - 0.550 mm 0.300 - 0.600 mm 1.200 mm

Index Engine - 10 Connecting rods and pistons - 105 Connecting rods and pistons - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Crankshaft and flywheel - 103

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Contents Engine - 10 Crankshaft and flywheel - 103

TECHNICAL DATA Crankshaft and flywheel General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Engine - Crankshaft and flywheel

Crankshaft and flywheel - General specification Crankshaft and bearing housings Crankshaft (balancing) Standard diameter of main seats Main seat diameter undersizes Main bushings bushes standard thickness Main bushings bushes undersizes (internal diameter) Play between the seats and the main bushings Maximum acceptable play from wear (main bushings) Link conrod seat standard diameter Link conrod seat diameter undersizes Link conrod standard thickness Link conrod internal diameter undersizes Play between the seats and the link conrod bushings Maximum acceptable play from wear (link conrod bushings) Crankshaft thrust link conrod standard thickness Thrust link conrod additional thicknesses Total width of thrust link conrods Width of crankshaft main bushings Longitudinal play of installed crankshaft Maximum longitudinal play from wear (crankshaft) Maximum ovalization and conicity of main seats and link conrod after grinding Maximum ovalization and conicity from wear of main seats and link conrod Maximum warping tolerance, supporting the crankshaft on the end seats Maximum acceptable tolerance, both directions, in the link conrod seat alignment (3 cylinder engine), or each pair of link conrod seats (4 cylinder engine) relative to the main seats. Maximum tolerance of eccentricity between the external surface of the main seats and the crankshaft center (imaginary line) Maximum permitted perpendicular tolerance for the flywheel support flange surface in relation to the crankshaft center, using a hundredths calibrator gauge supported on the front in a diameter of 108 mm (total calibrator gauge reading) Maximum permitted coaxial tolerance for the flywheel centering flange in relation to main seats (total calibrator gauge reading)

TL60E

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TL75E TL85E TL95E With integral counterweights 79.791 - 79.810 mm 0.254 - 0.508 mm / 0.762 - 1.016 mm 2.168 - 2.178 mm 0.254 - 0.508 mm / 0.762 - 1.016 mm 0.034 - 0.103 mm 0.180 mm 63.725 - 63.744 mm 0.254 - 0.508 mm / 0.762 - 1.016 mm 1.805 - 1.815 mm 0.254 - 0.508 mm / 0.762 - 1.016 mm 0.033 - 0.087 mm 0.180 mm 3.378 - 3.429 mm 0.127 - 0.254 mm / 0.381 - 0.508 mm 31.766 - 31.918 mm 32.000 - 32.100 mm 0.082 - 0.334 mm 0.400 mm 0.010 mm 0.050 mm 0.100 mm 0.250 mm

Âą0.100 mm

0.025 mm

0.040 mm

Index Engine - 10 Crankshaft and flywheel - 103 Crankshaft and flywheel - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel tanks - 216

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Contents Engine - 10 Fuel tanks - 216

SERVICE Fuel tank Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Auxiliary fuel tank Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Engine - Fuel tanks

Fuel tank - Drain fluid 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Remove the plug (1) to drain the fluid. 4. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

BRAG12TRLUE0562

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Engine - Fuel tanks

Fuel tank - Remove Prior operation: Fuel tank - Drain fluid (10.216) 1. Remove the screws (1) from the platform access ladder. Remove the ladder.

CUIL13TR00689AA

CUIL13TR00686AA

CUIL13TR00692AA

2. Loosen nuts (1) and (3). Remove the bolt (4) and the strap (2) . 3. Remove the rear left-hand wheel from the tractor. Consult the procedures in Rear wheels - Remove (44.520).

4. Remove hose (1).

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Engine - Fuel tanks

5. Remove the plate (1) by loosening the four bolts (4). 6. Remove the tubes (2) and (4). 7. Remove the rear fitting of the strap (5).

CUIL13TR00687AA

CUIL13TR00688AA

CUIL13TR00691AA

CUIL13TR00690AA

8. Loosen nuts (1) and (3). Remove the bolt (4) from its housing and remove the strap (2).

9. Remove the bolts (1) and (2) from the fuel tank support.

10. Remove the bolts (1) and (2) from the fuel tank support. Remove the fuel tank support. 11. Remove the fuel tank from its housing.

Next operation: Fuel tank - Install (10.216).

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Engine - Fuel tanks

Fuel tank - Install Prior operation: Fuel tank - Remove (10.216). 1. Position the fuel tank in its housing. 2. Install the fuel tank support by installing the four bolts. 3. Install the front and rear straps of the fuel tank. Apply a torque of 8 - 12 NÂˇm (6 - 9 lb ft). 4. Install the plate (1) by tightening the bolts (4). 5. Install the tubes (2) and (3).

CUIL13TR00687AA

CUIL13TR00692AA

6. Install the hose (1). 7. Install the rear left-hand wheel of the tractor. Consult the procedures in Front wheels - Install (44.511). 8. Install the platform access ladder.

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Engine - Fuel tanks

Auxiliary fuel tank - Drain fluid Auxiliary tank 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Remove the plug (1) to drain the fluid. 4. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

CUIL13TR00938AA

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Index Engine - 10 Fuel tanks - 216 Auxiliary fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel tank - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Fuel injection system - 218

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Contents Engine - 10 Fuel injection system - 218

TECHNICAL DATA Fuel injection system General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Rotary injection pump General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Fuel injection system Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Rotary injection pump Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Service instruction Bosch injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Service instruction Delphi DP 150 injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Timing adjust Bosch injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Timing adjust Delphi DP 150 injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Timing check Delphi DP 150 injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Bleed Bosch injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Bleed Delphi injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Fuel injectors Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Replace injector sleeves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

(*) See content for specific models 47835583 21/10/2015

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Engine - Fuel injection system

Fuel injection system - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

TL60E Turbocompressor GARRET type Injection pump BOSCH pump DELPHI pump Direction of rotation Injection order Injetores BOSCH type Injector port type Injector type DELPHI type Injector port type Injector type Number of holes Diameter of injector holes Calibration pressure BOSCH pump injection piping

TL75E

TL85E

TL90E

TA3118 - 0.82 A/R 57 With incorporated rotating distributor and automatic advance regulator VE 3/11F 1250 L 163 - 4794586 DELPHI DP 150 Counterclockwise 1-2-3 1-3-4-2 4800029 4791124 4800030

KBEL83S35

3 0.350 mm 230 - 242 bar

Type

4797506 -

Tube size

6 mm x 1.5 mm x 475 mm

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5 0.230 mm 0.250 mm 258.3 - 268.5 bar FPT/Cartec FPT/Cartec FPT/Cartec ( (504388200) (504388201) 5801445643) 6 mm x 6 mm x 6 mm x 1.8 mm x 1.5 mm x 1.5 mm x 540 mm 540 mm 540 mm

Engine - Fuel injection system

Rotary injection pump - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

Model TL75E TL85E TL95E

LA ---

LA --LA ---

Engine Engine Série 8000 - 55 kW to 2400 RPM/ 275 N·m to 4 Cil 1400 RPM 8000 Series 62 kW to 2500 RPM/ 310 N·m to – 4 Cyl 1400 RPM Série 8000 - 73 kW to 2400 RPM/ 380 N·m to 4 Cil 1400 RPM

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Risk angle

Lock angle

APMS angle

338 °

346 °

8°

340 °

351 °

11 °

340 °

348 °

8°

Engine - Fuel injection system

Fuel injection system - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

The fuel system consists of a reservoir, a feed pump, filters, a rotary injection pump, injectors, and tubing. The fuel injection pump is pressure-fed from the feed pump. The fuel flows from the fuel tank to the sediment separator filter, passes the feed pump, and continues to the filter. From the filter, the fuel continues to the injection pump, and then to the injectors. The injection pump supplies extra fuel to lubricate and cool the injectors. The excess fuel returns to the fuel tank, by means of the return line from the injectors.

Feed pump A suction pump for the diaphragm is located between the tank and the primary fuel filter. The pump draws fuel from the tank via the sediments (incorporated in lift pump) and passes fuel under pressure to the primary and secondary fuel filters and onto the fuel injection pump.

Fuel filters Rotary-type fuel filters located on the right-hand side of the engine receive the fuel from the suction pump. From the filter head, the fuel is diverted through the filter element and into the base chamber. The filtered fuel then rises through the central tube of the element to the filter head outlet, continuing to the injection pump.

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Engine - Fuel injection system

Rotary injection pump - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

For Bosch and Delphi injection pumps WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Remove the exhaust tube and open the hood. 2. Disconnect the negative battery cable. 3. Remove the protection screen (1) by loosening the three fixing bolts on the right-hand side of the blower.

LAIL11TL1275A0A

LAIL11TL1276A0A

4. Remove the throttle control return spring (1) and remove the throttle lever (2).

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Engine - Fuel injection system

5. Loosen the clamp (1) and disconnect the flexible tube (2) connected to the cold start device.

LAIL11TL1277A0A

LAIL11TL1278A0A

LAIL11TL1279A0A

LAIL11TL1280A0A

6. Disconnect the electric wires (1) from the starter motor solenoid.

7. Loosen the connections (1) from the supply pump and the connection (2) from the injection pump.

8. Loosen the connections from the fuel filter and remove tubes (1) and (2).

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Engine - Fuel injection system

9. Loosen the nuts from the injection pump to injector connecting tubes (1) and remove the tubes.

LAIL11TL1281A0A

LAIL11TL1282A0A

LAIL11TL1283A0A

10. Loosen the fixing bolts (1) from the injection pump control gear cover (2).

11. Remove the access cover to the flywheel rack (1).

12. Turn the flywheel with appropriate means until the two reference signs (4) marked on gears (1) and (2) match up.

LAIL11TL1284A0A

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Engine - Fuel injection system

13. Loosen the nut (1) fixing the injection pump shaft to the respective drive gear.

LAIL11TL1285A0A

LAIL11TL1286A0A

LAIL11TL1287A0A

LAIL11TL1288A0A

14. Loosen the fixing nuts (1) from the distribution gear box pump.

15. Extract the injection pump drive gear (1) using extractor 380000322 (2).

16. Remove the injection pump (1). NOTE: On the TL60E model, the fuel filter must be removed before removing the injection pump.

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Engine - Fuel injection system

17. Remove the gasket (1), the spacer (2) and the gasket (3).

LAIL11TL1289A0A

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Engine - Fuel injection system

Rotary injection pump - Service instruction Bosch injection pump TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

Calibration data for Bosch injection pump VE 3/11 F 1250 L 163 Model TL60E Pump point on the engine: Start of injection 5 - 7 ° before TDC on cylinder 1 in the compression stroke. Pre-displacement of the pumping element to be fitted at the pump point on the engine: 1 mm from BDC (with tool 380000228 - 380000229). Pump output connection for cylinder No. 1: Marked with the letter A.

Assembly sizes Symbol SUS (max.) KF MS ya yb

4.30 mm 5.1 - 5.3 mm 1.5 - 1.7 mm 37.9 - 39.9 mm 44.5 - 49.5 mm

Calibration test conditions Test bench conforms to standard ISO 4008/1.../2 Injectors conform to standard ISO 7440-A61 ( 1688901020 and pad with calibrated bore Ø 0.6 mm) Injector calibration: 172 - 175 bar (2494 - 2538 psi). Feed pressure: 0.30 - 0.40 bar (4.35 - 5.80 psi). Tubing (conforms to standard ISO 4093.2): 6 mm x 2 mm x 840 mm Burette emptying time: 30 in Test fluid: ISO 4113 at a temperature of 44 - 46 °C.

Pre-displacement of the pumping element from BDC 0.00 - 0.04 mm

Start of injection Pump rotation (control side): anti-clockwise

Injection order: 1-2-3

800 RPM

Advance variator displacement Advance displacement: 2.5 - 2.9 mm

800 RPM

Feed pump pressure Internal feed pressure: 3.8 - 4.4 bar

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Engine - Fuel injection system

Volume at full load Volume for 1000 injections: 68.5 69.5 cm³

750 RPM

Offset: < 3.5 cm³ (3.5 cm³)

Deviation curve with regulator on minimum Volume for 1000 injections: 21 Offset: < 3.5 cm³ (3.5 cm³) 25 cm³

350 RPM

Deviation curve with regulator on maximum Volume for 1000 injections: 18 Offset: - cm3 22 cm³

1400 RPM

Volume at starting rpm Volume for 1000 injections: 80 - 130 cm³

100 RPM

RPM Internal feed pressure

Evolution of transfer pressure 800 RPM 500 RPM 3.8 - 4.4 bar 2.5 - 3.1 bar

RPM Advance displacement

Evolution of injection advance 800 RPM 600 RPM 1200 RPM 2.5 - 2.9 mm (0.10 - 0.11 in) 0.8 - 1.6 mm (0.03 - 0.06 in) 5.6 - 6.4 mm (0.22 - 0.25 in)

RPM Return flow cm3/10 seconds

Return flow 0 RPM 41.7 - 83.4 (26.7 - 98.4)

1200 RPM 5.5 - 6.1 bar

1250 RPM 55.6 - 139 (40.6- 153)

NOTE: The volumes indicated above in parenthesis are to be used solely as check values. Evolution of flows Volumes for 1000 injections cm3 0 - 3 cm³ 18 - 22 cm³ ( 15.5 - 24.5 cm³ ) 42 - 58 cm³ 68.5 - 71.5 cm³ ( 66.5 - 73.5 cm³ ) 68.5 - 69.5 cm³ ( 66 - 72 cm³ ) 59 - 62 cm³ ( 57 - 64 cm³ )

RPM 1460 RPM 1400 RPM 1350 RPM 1250 RPM 750 RPM 500 RPM

RPM Volume for 1000 injections

Flow check at minimum rpm 350 RPM 21 - 25 cm³ ( 19 - 27 cm³ )

475 RPM 0.0 - 3.0 cm³

NOTE: The volumes indicated above in parenthesis are to be used solely as check values. RPM 1250 RPM

Mechanical zero (stoppage) flow Voltage 12 V

Volumes for 1000 injections cm3 0 - 3 cm³

RPM 350 RPM

Electrical zero (stoppage) flow Voltage (volts) -

Volumes for 1000 injections cm3 0 - 3 cm³

RPM 100 RPM 250 RPM 350 RPM

Automatic starting flow evolution Volumes for 1000 injections cm3 80 - 130 cm³ 25 - 65 cm³ 90 - 140 cm³

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Bench test data Test conditions Relative humidity: 65 - 75 % Fixed injection advance from TDC of cylinder no. 1 in the compression stroke (See the table Evolution of injection advance). Engine without fan, air filter, and exhaust muffler Ambient temperature: 17 - 23 Â°C Atmospheric pressure: 735 - 745 mm Hg (Turim altitude) Specific gravity of diesel oil 820 - 840 g/L Throttle lever Load applied on Engine RPM Corresponding power with the engine Fuel consumption position brake running for: 2 hours 50 hours > 40.4 kW > 41.9 - 44.1 kW To develop 9.7 - 10.2 kg/hr 2500 RPM Maximum (54.93 Hp) (56.97 - 59.96 Hp) maximum power > 28.3 kW 29.4 - 31.25 kW To develop 6.4 - 6.8 kg/hr1500 RPM Maximum (38.48 Hp) (39.97 - 42.49 Hp) maximum torque Null (on empty) Maximum 2750 - 2790 RPM Null (on empty) Minimum 625 - 675 RPM

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Rotary injection pump - Service instruction Delphi DP 150 injection pump Injection pump calibration data Models TL75E, TL85E and TL955E Injection pump pumping element at start of stroke (BDC) obtained with tool 380000215 (manual pump to test injection nozzles), applying Diesel oil pressure at injection pump output U. Pump output connection on cylinder No. 1: marked with the letter U.

Pumping element at BDC

1. Start of injection Pump rotation (control side): anti-clockwise

Calibration test conditions Test bench according to norm ISO 4008/1.../2 Injectors according to Standard ISO 7440-A61 (1688901020 and pad with calibrated orifice Ă&#x2DC; 0.6 mm). Injector calibration: 172 - 175 bar (2494 - 2538 psi). Feed pressure: 0.3 - 0.4 bar. Tubing (according to Standard ISO 4093.2): 6 x 2 x 840 mm. Burette emptying time: 30 ". Test fluid: ISO 4113 at a temperature of 44 - 46 Â°C. To see the timing procedure for the Delphi injection pump, check the steps in Rotary injection pump General specification (10.218).

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Injection order: 1- 3 - 4 - 2

Engine - Fuel injection system

Rotary injection pump - Timing adjust Bosch injection pump If the engine is running irregularly, if reference signs (1) are missing, or if doubts arise about its accuracy, the pump must be synchronized as follows: 1. Loosen the nuts from the injection pump to the injector connecting tubes (1).

LAIL11TL1281A0A

LAIL11TL1101A0A

LAIL11TL1102A0A

2. Remove injection pump gear cover. Check the reference numbers marked on gears (1) and (2) match.

3. Remove the flywheel inspection cover (1). Rotate the crankshaft to bring up cylinder no. 1 to Top Dead Center (TDC) in the compression stroke.

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4. Check through the flywheel inspection hole that the alignment of the reference arrow with the degree mark is of:

Models TL60E

LAIL11TL1311A0A

LAIL11TL1312A0A

LAIL11TL1313A0A

Degrees Before Top Dead Center (BTDC) Between 5 Â° and 7 Â°

5. With the injection pump installed in the respective housing and fixing bolts loose, remove the plug (1) installed in the pump body.

6. Install the calibrator 380000228 ( (1), Fig. 7) and the tool 380000229 (2), pre-loading the calibrator to approximately 2.5 mm. 7. Then slowly turn the flywheel backwards until lifting the pumping element (of the injection pump) to BDC in the start of pumping position (made evident by the comparing gauge arrow that stops lowering). 8. Set the comparing gauge arrow to zero and slowly turn the flywheel to the right (seen from the fan side) until reaching the reference index corresponding to the degree marking on the flywheel. 9. Check on the calibrator gauge if the pumping element travel is 1 mm, if not, loosen the pump fixing bolts. 10. Turn the pump anti-clockwise if travel is lower and clockwise if travel is higher until obtaining the specified travel.

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11. Once these conditions have been reached, tighten the pump fixing nuts ( (1), with a torque of 25 NÂˇm (18.44 lb ft).

LAIL11TL1286A0A

LAIL11TL1099A0A

12. Mark pump point references ( (1))) on the housing, on the pump and on the interface spacer. 13. Remove the calibrator 380000228 (1) and the tool 380000229 (2), refit the cover, tightening it to a torque of 8 - 10 NÂˇm (5.90 - 7.38 lb ft). 14. Reassemble the other parts proceeding in the inverted order in relation to the operations.

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Rotary injection pump - Timing adjust Delphi DP 150 injection pump TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA ---

NOTE: The following procedure ensures an accuracy of approximately 1 Â° of tolerance if the engine is at top dead center (TDC) during assembly. 1. With the pump on a workbench, partially loosen the side bolt (1) and move the spacer ferrule (2) to the unlock position (3). Tighten the bolt and lock the ferrule. This way, the fuel pump shaft can turn freely. NOTICE: Starting the engine with the pump shaft locked can cause serious damage to the injector pump.

CUIL14TR01371AA

CUIL14TR01373AA

CUIL14TR01374AA

2. Assemble the keyway (1) on the pump shaft (2).

3. Assemble the gear (1) on the shaft with the washer (3) and the nut (2).

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4. Assemble the protractor angle 380003211 (1). Align the tongue (2) of tool with the dash (3) in the injection pump casing.

CUIL14TR01376AA

5. Adjust the grade per the angle for each injection pump by turning counter-clockwise. Refer to Rotary injection pump - General specification (10.218).

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Engine - Fuel injection system

Rotary injection pump - Timing check Delphi DP 150 injection pump TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA ---

Procedure on workbench 1. Place the engine at top dead center (TDC) with the first cylinder in compression.

LAIL11TL1317A0A

CUIL14TR01372AA

CUIL14TR01373AA

2. Place the lock bolt (1) of the pump into the lock position.

3. Assemble the keyway (1) on the pump shaft (2).

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4. Assemble the gear (1) on the shaft with the washer (2) and the nut (3).

CUIL14TR01374AA

CUIL14TR01375AA

5. Assemble the angle protractor 380003211 (1). Measure the angle.

4. Compare the angle measured by the tool 380003211 with the values specified in Rotary injection pump General specification (10.218).

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Engine - Fuel injection system

Rotary injection pump - Bleed Bosch injection pump TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

1. Loosen the plug (1) on the first filter.

LAIL11TL1325A0A

LAIL11TL1326A0A

LAIL11TL1327A0A

2. Activate the lever (1) on the injection pump until fuel flows out from the filter hole without air bubbles, then retighten the plug ( (1), Fig. 1).

3. Loosen the nut (1) on the injection pipe, start the engine, and having ensured no more air bubbles are coming out, tighten the nut (1).

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Rotary injection pump - Bleed Delphi injection pump TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA ---

1. Loosen the filter plug (1).

CUIL13TR01251AA

LAIL11TL1326A0A

LAIL11TL1327A0A

2. Activate the lever (1) on the injection pump until fuel flows out from the filter hole without air bubbles, then retighten the plug ( (1), Fig. 1).

3. Loosen the nut (1) on the injector line. Start the engine. After you verify that no more air bubbles are coming out, tighten the nut (1).

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Rotary injection pump - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Synchronization adjustment for TL60E, see the procedures in Rotary injection pump - Timing adjust Bosch injection pump (10.218) . Prior operation: Synchronization adjustment for TL75E, TL85E and TL95E, see the procedures in Rotary injection pump - Timing adjust Delphi DP 150 injection pump (10.218).

For Bosch and Delphi injection pumps 1. Reassemble the gear cover. 2. Reassemble the two semi-rigid tubes connecting the injection pump/filter and supply pump/filter. 3. To make it easier, first fasten the connections to the filter. 4. Assemble the engine stopping cable. Reassemble the high pressure tubes to the pump and injectors. 5. Reassemble the injection pump throttle control lever articulation spring. Reassemble all the flexible tubes that were disassembled before. 6. Reinstall the access cover to the flywheel rack. 7. Reassemble the protection screen on the RH side of the fan. 8. Reconnect the negative battery cable. 9. Close the hood and reassemble the exhaust tube.

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Fuel injectors - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Disconnect the negative battery cable from the battery. 2. Fasten lifting chains to the hood (1) and then adjust the winch chains. 3. Perform steps 7, 8 and 9 described in . Engine - Remove (10.001) .

LAIL11TL1328A0A

LAIL11TL1332A0A

4. Remove the connection (1) from the injector fuel sealing tubes.

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Engine - Fuel injection system

5. Remove the connection (1) from the injector fuel high pressure line.

LAIL11TL1333A0A

LAIL11TL1334A0A

6. Loosen the two retainer nuts (1) and remove the injector.

Next operation: Injector leak tests: consult the procedures in Fuel injectors - Leakage test (10.218).

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Engine - Fuel injection system

Fuel injectors - Leakage test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Removal of the fuel injector, see the procedures in Fuel injectors - Remove (10.218). NOTICE: The spray from a fuel injector tester can pierce human skin with fatal results. When an injector is spraying, the nozzle holder should be turned away from the operator and other persons. During the nozzle opening pressure and spray pattern tests, collect the spray in a container partly filled with rags to absorb the spray. When conducting the Nozzle Seat Leakage Test, release the injector tester pump pressure before touching the nozzle tip with a sheet of blotting paper. The spray is flammable: make sure no open flames are in the test area and do not generate excess vapor.

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Injector Testing and Overhaul Adjusting the spray opening pressure: • Pump the measurement device slowly and note the pressure at which the needle valve lifts when the fuel is injected into the injector nozzle. The minimum acceptable opening pressure is 260 bar (3770.00 psi). If the opening pressure is less than 260 bar, adjust it to 260 - 272 bar (3770.00 - 3944.00 psi). Spray pattern: • Pump the tester rapidly (80 - 90 strokes per/min) and observe the spray pattern from the holes. An atomised spray free from distortion and irregular streaks of fuel should be observed. The tester is not regarded as providing a suitable test for atomisation under working conditions, but gives an indication of the working of the nozzle. Leak from the spray seat:

LAIL11TL1335A0A

LAIL11TL1336A0A

• Dry the spray point and apply a pressure of 10 bar (145.00 psi) below the opening pressure. The nozzle tip and bottom face must remain essentially dry and there must be no tendency for blobs of fuel to collect or drip. A slight dampness can be ignored. If there is any leakage from the nozzle seat, the nozzle assembly must be cleaned or replaced. Leak from the rear part of the injector: • Apply a pressure of 10 bar (145.00 psi) below the opening pressure after loosening the handle and timing the drop in pressure. The pressure must fall 100 150 bar between 5 - 45 s. If the pressure falls by less than 5 s, the injector assembly must be replaced. If the pressure takes longer than 45 s to fall, check for carbonization in the rear orifices. NOTE: If the injectors pass the tests, re-fit them on the engine. Otherwise, take them to an approved service center for further tests and repairs.

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Fuel injectors - Replace injector sleeves TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

If the cylinder head has been machined, check that the fuel injector projection is the projection shown in the figure to the side. • Injector projection: 0.05 - 0.70 mm • Maximum permissible projection: 1.00 mm If projection is more than 1.00 mm, replace the injector sleeve as follows: 1.

Fasten the extractor sleeves (Special tool No. 293784 (1) to the fixing nuts of the head (2) on the retainer studs of the injector.

Rotate the nut (3) to extract the sleeve (4) from its housing on the head.

LAIL11TL1386A0A

LAIL11TL1387B0A

Installing a new sleeve 1. Install O-rings (2) on the sleeve. Insert the sleeve in the housing using Special Tool 380000834. Make sure that the lower part is in contact with the seat of the head.

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2. Position the special tool 380000830 (1) in the new sleeve. Secure the bushing in the seat by tightening the nut (2) counter-clockwise. Insert the special tool 380000831 (3) in the bushing (1) and then in the lower part of the sleeve.

LAIL11TL1388B0A

LAIL11TL1389B0A

3. Remove the tool 380000831. Fit the tool 380000833 (1) to adjust the seat of the injector so that the surface is smooth and free of burrs or tool marks.

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4. Insert the injector in the sleeve and check that the projection is between 0.05 - 0.7 mm.

LAIL11TL1390B0A

Next operation: Assembling the injector sleeves, see the procedures in Fuel injectors - Assemble (10.218).

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Fuel injectors - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Injector leak tests: consult the procedures in Fuel injectors - Leakage test (10.218). Proceed as follows: 1. Assemble the injectors (2) in their respective housings. 2. Position the supports. Assemble the base ball washers.

BRAG11TR0102LUE

LAIL11TL1337A0A

3. Tighten the nuts (1) manually until they touch the ball washers. Use a torque meter to tighten them to the indicated torque in two successive stages: • 1st stage: tighten the nuts to 10 N·m (7.38 lb ft) • 2nd stage: tighten the nuts to 25 N·m (18.44 lb ft) 4. Tighten the injector return tube. 5. Tighten the fixing nut from the high-pressure tubes to the injectors.

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Index Engine - 10 Fuel injection system - 218

(*)

Fuel injection system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injection system - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fuel injectors - Replace injector sleeves (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Bleed Bosch injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Bleed Delphi injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Service instruction Bosch injection pump (*) . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Service instruction Delphi DP 150 injection pump . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Timing adjust Bosch injection pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Timing adjust Delphi DP 150 injection pump (*) . . . . . . . . . . . . . . . . . . . . . . .

Rotary injection pump - Timing check Delphi DP 150 injection pump (*) . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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Engine - 10 Intake and exhaust manifolds and muffler - 254

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

SERVICE Exhaust muffler Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Remove CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A

Prior operation: Side shield - Remove (90.102) .

Aspirated tractors 1. Remove the nuts (3) and (4) from the clamp and remove the exhaust pipe. 2. Remove nuts (1) and (2) that secure the muffler on the exhaust manifold. 3. Remove the support (5) fastening bolts and remove the exhaust assembly.

CUIL13TR00844AA

CUIL13TR00330AA

CUIL13TR00328AA

Turbine tractors 1. Remove nuts (2) and (3) and remove the exhaust (1).

2. Remove all the bolts (1) that secure the muffler (2) on the turbine. 3. Remove the plate (3) fastening bolts and remove the exhaust assembly.

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Engine - Intake and exhaust manifolds and muffler

Exhaust muffler - Install Prior operation: Exhaust muffler - Remove (10.254)

CAUTION Burn hazard! Exhaust surfaces are hot! Always wear protective gloves when cleaning or working on or near the muffler, catalytic converter, or exhaust stack. Failure to comply could result in minor or moderate injury. C0142A

Aspirated tractors 1. Place the exhaust assembly in its housing and install the support (5) fastening bolts. 2. Install nuts (1) and (2) on the clamp that secure the muffler on the exhaust manifold. 3. Install nuts (3) and (4) on the clamp that secures the exhaust on the support.

CUIL13TR00844AA

CUIL13TR00328AA

CUIL13TR00330AA

Turbine tractors 1. Place the exhaust assembly in its housing and install the support (3) fastening bolts. 2. Install the bolts (1) that secure the muffler (2) on the turbine.

3. Install nuts (2) and (3) on the clamp that secures the exhaust (1) on the support.

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Index Engine - 10 Intake and exhaust manifolds and muffler - 254 Exhaust muffler - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Exhaust muffler - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine - 10 Engine cooling system - 400

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Contents Engine - 10 Engine cooling system - 400

SERVICE Radiator Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Interior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Engine - Engine cooling system

Radiator - Drain fluid The system uses a mixture of water and an additive. This additive has antioxidant, anticorrosive, and antifoam properties. It also prevents freezing, provided that it is used in the right proportion, which depends on the ambient temperature. Consult the following table: Temperature ( oC) Amount of additive (% by volume)

-8 20

-15 30

-25 40

-30 50

To change the coolant, carry out the following procedures: 1. Remove the cap (1) from the radiator.

BRAG12TRLUE0567

CUIL13TRO0193AA

BRAG12TRLUE0567

2. Remove the plug (1) and drain the coolant by the plug. NOTE: If the objective is to clean the inside of the cooling circuit, disconnect the lower radiator hose and then circulate clean water under pressure from the system. 3. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country. 4. Reinstall the lower plug (1) or reconnect the hose, as applicable.

5. Fill the system with the recommended proportion of additive and then fill with clean water. 6. Fill slowly to eliminate the air contained in the system. 7. After filling, run the engine for a few minutes to allow the water and additive to mix completely. 8. Switch off the engine and fill to the level by the filler nozzle (1). NOTICE: Immediately request a repair of any damaged part of the cooling system and top up to the correct level with the water and additive mixture, as shown in the table above.

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Engine - Engine cooling system

Radiator - Interior washing Cleaning the radiator - Cab models For cab models, proceed as follows: 1. The heating system uses the engine cooling liquid, which circulates between this and the radiator. 2. Drain the system as outlined previously. 3. However, to drain the system completely, set the temperature control (1) all the way to the right.

CUIL13TRO0192AA

BRAG12TRLUE0567

4. Fill the system with the recommended proportion of additive and then fill with clean water. 5. Install the cover (1). 6. Position the temperature control (1), figure 1, to the position (A) and accelerate the engine to maximum rpm for 5 min. 7. Remove the cap (1) and turn the temperature control to the vertical position and accelerate the engine up to full power for 5 min. 8. Fill the cooling system with the engine at a high rpm to obtain the maximum level. 9. Refit the cap (1) on the filler nozzle.

Cleaning the radiator - Platform models A more rigorous internal cleaning of the system as described above is only necessary when the machine is operating with coolant that does not contain the recommended additive.

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Engine - Engine cooling system

1. With the engine cold, drain the system by removing the plug (1). After draining, reinstall the plug (1). 2. Fill it with a Solvay soda and water solution, made up of 250 g soda for every 10 l of water. 3. Start the engine and leave it idling for 1 h, then drain the solution. 4. Wait for the engine to cool down, then run distilled water through the radiator at the same time as it is drained from the plug (1). 5. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country. 6. Reinstall the plug (1), fill with water, start the engine and leave it idling for a few minutes and drain the system. 7. Let the engine cool down and refill the system with water and additive until reaching the relevant level. NOTICE: The engine must not be running when water is drained.

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CUIL13TRO0193AA

Index Engine - 10 Engine cooling system - 400 Radiator - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Radiator - Interior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

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

47835583 21/10/2015 EN

SERVICE MANUAL Clutch TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Clutch - 18

[18.110] Clutch and components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18.1

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CONSUMABLES INDEX Consumable Loctite® Loctite®

Reference Clutch - Install Clutch - Install

PAGE 18.1 / 22 18.1 / 22

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Contents Clutch - 18 Clutch and components - 110

TECHNICAL DATA Clutch General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Clutch Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Clutch control mechanism Clutch control mechanism - Adjust - Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Clutch Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Disassemble - Double disk clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble - Double disk clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Alignment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

DIAGNOSTIC Clutch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

(*) See content for specific models 47835583 21/10/2015

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CONSUMABLES INDEX Consumable Loctite® Loctite®

Reference Clutch - Install Clutch - Install

PAGE 18.1 / 22 18.1 / 22

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Clutch - Clutch and components

Clutch - General specification Clutch 11 in / 11 in TL60E Group of two clutches with one dry disc Mechanical: with a pedal for the master clutch, with a manual lever for the PTO clutch Plate spring, single Organic agglomerates 9.7 - 10.3 in 7.3 - 7.9 mm 0.050 - 0.151 mm

Type Control system Engagement and release mechanism Type of cladding for activated discs Thickness of the main clutch drive discs Thickness of the Power Take-Off (PTO) clutch drive discs Play between the collar of the master clutch and the respective housing Clearance between the Power Take-Off (PTO) clutch collar and the respective housing

0.060 - 0.180 mm

Clutch - General specification 12 in Clutch TL75E Type Control system Engagement and release mechanism Type of lining of driven disk Thickness of the main clutch friction discs Gap between the disengagement collar and the respective support

TL85E Dry disc Mechanical, with pedal Diaphragm spring Organic agglomerate 9.7 - 10.3 mm

TL95E

0.050 - 0.151 mm

Clutch - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Clutch 12 in / 12 in Type Control system Engagement and release mechanism Type of lining of the main clutch drive discs Type of lining of the Power Take-Off (PTO) clutch drive discs Thickness of the main clutch friction discs Thickness of the PTO clutch friction discs Play between the collar of the master clutch and the respective housing

TL75E TL85E TL95E Group of two clutches with one dry disc Mechanical: with a pedal for the master clutch, with a manual lever for the PTO clutch Plate spring (Belleville) Ceramic-metallic agglomerates

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Organic agglomerates 9.6 - 10.4 in 7.3 - 7.9 mm 0.050 - 0.0151 mm

Clutch - Clutch and components

Play between the collar of the PTO clutch and the respective housing

0.060 - 0.180 mm

Clutch - Torque Parts Engine flywheel clutch fixing bolts 11 in/ 11 in Collar control shaft fixing bolts Engine clutch fixing bolts Cover fixing nuts

Turnbuckle M8 X 1.25 M16 x 1.5 M12 x 1.25 M8 X 1.25

Torque value 25 N·m (18 lb ft) 157 N·m (116 lb ft) 98 N·m (72 lb ft) 17 N·m (13 lb ft)

Turnbuckle M16 x 1.5 M10 X 1.25 M12 x 1.25 M8 X 1.25

Torque value 157 N·m (116 lb ft) 59 N·m (44 lb ft) 98 N·m (72 lb ft) 17 N·m (13 lb ft)

Clutch - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Parts Collar control shaft fixing bolts Engine flywheel clutch fixing bolts 12 in/ 12 in Engine clutch fixing bolts Cover fixing nuts

Clutch - Service limits CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Double disc clutch 11 in / 11 in Reference (1) (2) (3) (4) (A) (B) (C) (D)

Engine flywheel Power Take-Off (PTO) clutch pressure disc Main clutch pressure disc Clutch Cover 15.5 mm (0.6 in) 22.70 mm (0.89 in) 71.40 mm (2.81 in) 55.60 mm (2.19 in)

LAIL11TL0409A0A

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Clutch - Clutch and components

Maximum dimensions allowed for servicing Check the friction surface conditions of the clutch cover pressure discs. In general, you can remove up to 1 mm of material from friction surfaces on support covers for the cast iron clutch (4) and pressure plate rings (3) and (2) and the engine flywheel (1). NOTICE: The maximum size for servicing of the engine flywheel is 1 mm.

LAIL11TL0409A0A

LAIL11TL0412A0A

LAIL11TL0409A0A

A recess of 0,5 mm needs to be re-established after servicing the engine flywheel.

If necessary, service the Power Take-Off (PTO) clutch pressure disc friction surface (2). Remember that the value of the material removed with regards to the correct rate (A) must also be removed from the cover support base (4) to re-establish the original pressure of the disc position (2) in relation to the engine flywheel.

When servicing the friction surfaces on the pressure ring of the main clutch (3) or the clutch cover (4), remember that the removal of material cannot be compensated for by using the clutch cover (4). NOTICE: Remove the smallest amount of material possible on parts (3) and (4) to extend the life of the clutch. NOTE: If the main clutch friction disc starts to slide after servicing the parts (3) and (4), it will be necessary to replace the entire clutch.

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Clutch - Clutch and components

Clutch - Service limits CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Single clutches 11 in and 12 in Worn single clutch parts should not be serviced. Replace the clutch assembly when it has defects. When installing the new clutch, check the allowable dimensions for servicing of the engine flywheel as indicated in the figure to the side.

LAIL11TL0411A0A

Clutch - Service limits TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

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Clutch - Clutch and components

Double disc clutch 12 in/ 12 in Reference (1) (2) (3) (4) (A) (B) (C) (D)

Engine flywheel Power Take-Off (PTO) clutch pressure disc Main clutch pressure disc Clutch Cover 13.10 mm (0.52 in) 24.50 mm (0.96 in) 79.80 mm (3.14 in) 58.10 mm (2.29 in)

Check the wear on the PTO friction discs (11) and on the main clutch (9) and replace if the sheaths are spent or nearly spent on the friction material planes. See the sectional view of the clutch in Clutch - Sectional view (18.110).

LAIL11TL0410A0A

LAIL11TL0413A0A

Replace the disc if the organic build-up surfaces are soaked in oil.

A recess of 0,5 mm needs to be re-established after servicing the engine flywheel.

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Clutch - Clutch and components

LAIL11TL0410A0A

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Clutch - Clutch and components

Clutch - Sectional view Clutch 11 in / 11 in 1.

Adjust the release levers of the Power Take-Off (PTO) clutch

Plate spring (Belleville)

Engine clutch box fixing bolts and nuts

PTO clutch release levers

PTO and main clutch disengage control sleeves, complete with collars

Nuts for fastening the sleeve cover

Fork fixing bolt

Main clutch release lever

Main friction disc

10. Main clutch release lever adjustment 11. PTO friction disc 12. Engine flywheel bearing D = 97.5 mm Nominal distance of the release levers (8) from the engine flywheel clutch support plane. D1 = 139.5 mm Nominal distance of the release levers (4) from the engine flywheel clutch support plane. LAIL11TL0943B0A

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Clutch - Clutch and components

Clutch - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

12 in Clutch 1. Main clutch disc 2. Diaphragm spring 3. Disengage control sleeve, complete with axial bearing (collar) 4. Nuts for fastening the sleeve cover 5. Fork fixing bolt 6. Engine clutch box fixing bolts and nuts

LAIL11TL0942B0A

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Clutch - Clutch and components

Clutch 12 in/ 12 in

LAIL11TL0943F0A

Reference (1) (2) (3) (4) (5) (6)

Component Adjust the release levers of the Power Take-Off (PTO) clutch Plate spring (Belleville) Engine clutch box fixing bolts and nuts PTO clutch release Ievers PTO and main clutch disengage control sleeves, complete with collars Nuts for fastening the sleeve cover

Reference

Component

(7)

Fork fixing bolt

(8) (9) (10)

Main clutch release lever Main friction disc Main clutch release lever adjustment

(11)

PTO friction disc

(12)

Engine flywheel bearing

D = 102.5 mm. Nominal distance of the release levers (8) from the engine flywheel clutch support plane. D1 = 144.5 mm. Nominal distance of the release levers (4) from the engine flywheel clutch support plane.

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Clutch - Clutch and components

Clutch control mechanism - Adjust - Pedal When the clutch pedal position (2) needs to be adjusted or when the clutch has been checked, check the distance (A) from the main clutch command pedal so that the distance is 199.0 mm (7.8 in) + 5.0 mm (0.2 in) (with floor mat) from the platform for tractors without a cab and 176.0 mm (6.9 in) + 5.0 mm (0.2 in) (with floor mat) for tractors with a cab. Otherwise, adjust as follows: 1. Loosen the handles (1) and remove the cap to access the adjustment controls.

LAIL11TL0418A0A

LAIL11TL0419A0A

LAIL11TL0418A0A

CUIL13TR00684AA

2. Loosen the jam nuts (1) and turn the rod (2) to the left. 3. Check that the distance (A) is correct. 4. Tighten the locknuts (1).

5. Check again if the pedal travel is as specified. 6. Retighten the buttons (1)

NOTE: In tractors with mechanical PTO, the clearance of the Power Take-Off (PTO) drive should be adjusted, so that when moving the lever forward, there is a clearance (1) of approximately 4 - 7 mm between the lever and the cover of the lever.

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Clutch - Clutch and components

Clutch - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Engine - Remove (10.001) . 1. Disconnect the negative (â&#x2C6;&#x2019;) battery cable (1) from the battery.

CUIL13TRO0194AA

LAIL11TL0421A0A

2. Remove the spacer (1) installed between the engine and the transmission.

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Clutch - Clutch and components

3. Place a fixed trestle (1) under the counterweight cradle and block the front wheels with wooden wedges (2).

LAIL11TL0422A0A

LAIL11TL0423A0A

4. Insert tool number 380000292 (1) into the clutch disc. 5. Loosen the six fixing bolts from the clutch to the engine flywheel and completely remove the clutch assembly.

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Clutch - Clutch and components

Clutch - Disassemble - Double disk clutch TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Loosen the three Power Take-Off (PTO) clutch adjustment nuts (1).

LAIL11TL0398A0A

LAIL11TL0399A0A

LAIL11TL0400A0A

2. Remove the pressure plate (1) with the three helical springs (2) and the three washers.

3. Place the three clips (1) at 120 Â° on the clutch body and progressively and carefully compress the spring washer (Belleville).

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Clutch - Clutch and components

4. Remove the six retaining spring clips (1) from the respective seats.

LAIL11TL0397A0A

LAIL11TL1096A0A

LAIL11TL0401A0A

LAIL11TL1097A0A

5. Remove the three clips and remove the spring washer (1).

6. Loosen the three jam nuts (1) from the main clutch lever adjustment bolts.

7. Loosen the three main clutch lever adjustment bolts (1).

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Clutch - Clutch and components

8. Remove the main clutch pressure plate.

LAIL11TL0403A0A

LAIL11TL0404A0A

9. Remove the main clutch friction disc (1).

10. Remove the PTO clutch control lever springs (1).

LAIL11TL0405A0A

LAIL11TL0406A0A

11. Remove the PTO clutch articulation pins (1).

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Clutch - Clutch and components

12. Remove the main clutch control lever springs (1).

LAIL11TL0407A0A

LAIL11TL0408A0A

13. Remove the main clutch control lever springs articulation pin (1).

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Clutch - Assemble - Double disk clutch TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Reinstall the lever articulation pins for the respective springs.

LAIL11TL0408A0A

LAIL11TL0404A0A

LAIL11TL0403A0A

2. Reinstall the master clutch disc in the clutch box. NOTE: Make sure that the disk is installed with the splined hub projection facing the front of the machine (engine flywheel side).

3. Install the main clutch pressure disc (1). Install the clutch disk attachment bolts.

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Clutch - Clutch and components

4. Support the plate spring and carefully place the three clips (1). 5. Compress the spring progressively.

LAIL11TL0400A0A

LAIL11TL0397A0A

LAIL11TL0399A0A

LAIL11TL0398A0A

6. Insert the six lock clips (1), making sure that they are properly placed in the housings and remove the clips (1), figure 4.

7. Install the PTO clutch friction disc (1). Insert the three washers and the three helical springs (2) on the articulation pins. NOTE: Make sure that the PTO disk is installed with the splined hub projection facing the rear part of the machine (transmission).

8. Tighten the three nuts (1).

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Clutch - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Install the clutch using the tool 380000292 (1). Lock the clutch on the engine flywheel fastening it with the six bolts. 2. Adjust the height of the clutch disengagement levers. Consult the procedures in Clutch - Alignment (18.110). 3. Clean the clutch housing spacer and contact surface. Clean the old sealing paste from the engine surface. 4. Apply anaerobic sealant LOCTITE® on the engine and spacer contact surfaces. Assemble the spacer to the studs threaded on the engine. LAIL11TL0423A0A

5. Apply anaerobic sealant LOCTITE® on the clutch housing surfaces. 6. Place wooden blocks under the rear wheels, checking that the parking brake is on and the fixed trestles are correctly placed. 7. Approach the front shaft motor assembly from the clutch box side, pushing the front wheels. Pay attention to the oil suction rigid tubes and the pressure tube in the front drive engagement control distributor. 8. Turn the engine fan to enable the splined sleeve to fit into the Power Take-Off (PTO) shaft. 9. Tighten well all the clutch housing motor fixing bolts. 10. Tighten the brake line support clamp on the RH side of the engine. Lower the winch and disconnect the handrail cables. 11. Lower the trestles from the lower part of the engine sump and the clutch housing. Remove the splitter kit and the trestle from under the draw bar support. Lock the cab, fastening it with two front bolts. Next operation: Mechanical transmission - Install - Machines with cab (21.114) . Next operation: Mechanical transmission - Install – Machines with platform (21.114) .

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Clutch - Clutch and components

Clutch - Alignment TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Clutch - Install (18.110) . 1. Install the centering tool 380000292 (3) and assemble the entire clutch with the Power Take-Off (PTO) disk on the engine flywheel, tightening the fastening bolts (1). 2. Install the tool 380000293 (2) and adjust the main clutch release lever height until they are all the same (contact the template base in the same way).

LAIL11TL0414A0A

LAIL11TL0415A0A

3. Turn the tool 380000293 (2) and adjust the coplanarity for the release lever on the PTO clutch. 4. Remove the tools.

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Clutch - Check Single clutches 1. Install special tool 380000292 (1). 2. Remove the bolts (2) and remove the clutch assembly.

LAIL11TL0416A0A

LAIL11TL0417A0A

3. Verify the disc wear (1). Replace the disc if the plate fixing rivets of the plate planes are worn out or nearly worn out. 4. Replace the plateau assembly (2) if it has deep scratches or blue discoloration. NOTE: Make sure that the disc is installed with the splined hub projection facing the front of the machine (engine flywheel side).

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Clutch - Clutch and components

Clutch - Troubleshooting Problem Clutch slips

The clutch drags

The clutch is stuck and drags

Possible Cause Flywheel pressure plate and friction disc wear. Deformed or failed plate spring. Oil or grease the disc friction material.

Correction Replace the worn parts and adjust the clutch controls and levers. Replace the spring washer Replace the discs: eliminate the cause of the lubricant present in the clutch box and clean the friction surface. Hardening of external controls. Check joints, clean and lubricate. Replace the discs and adjust the clutch Deformed friction discs. control lever. The clutch disc hub springs have failed. Replace friction disc. Oil or grease the rubbing friction disc sur- Replace the discs: eliminate the cause of faces. the lubricant present in the clutch box and clean the friction surface. Replace the discs and adjust Deformed friction discs Seizing of external controls

Clutch noisy when engaging and/or disengaging Clutch bearing too hard when pressed

Commands not adjusted properly Worn axial bearing housing

Check, replace the damaged parts and lubricate. Adjust the commands Replace the bearing housing

Friction disc with damaged hub springs Hardening of external controls.

Replace the disc Check joints and lubricate them.

Hardening of pedal joint.

Check joints and lubricate them.

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Index Clutch - 18 Clutch and components - 110

(*)

Clutch - Alignment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Assemble - Double disk clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Disassemble - Double disk clutch (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Service limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Service limits (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Clutch control mechanism - Adjust - Pedal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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

47835583 21/10/2015 EN

SERVICE MANUAL Transmission TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Transmission - 21

[21.114] Mechanical transmission . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.1 [21.160] Creeper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.2 [21.162] Reverser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21.3

47835583 21/10/2015

CONSUMABLES INDEX Consumable Loctite® Loctite® Loctite® Loctite® Loctite® Loctite® Loctite® Loctite®

515™ 515™ 515™ 515™ 515™ 515™ 515™ 515™

Reference Mechanical transmission - Sectional view Mechanical transmission - Sectional view Mechanical transmission - Sectional view Creeper - Sectional view Creeper - Assemble Reverser - Sectional view Reverser - Sectional view Reverser - Assemble

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Transmission - 21 Mechanical transmission - 114

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Contents Transmission - 21 Mechanical transmission - 114

TECHNICAL DATA Mechanical transmission General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Mechanical transmission Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

SERVICE Mechanical transmission Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Remove - Machines with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Remove â&#x20AC;&#x201C; Machines with platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Install - Machines with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Install â&#x20AC;&#x201C; Machines with platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Transmission housing Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

(*) See content for specific models 47835583 21/10/2015

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™ Loctite® 515™

Reference Mechanical transmission - Sectional view Mechanical transmission - Sectional view Mechanical transmission - Sectional view

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PAGE 21.1 / 9 21.1 / 11 21.1 / 15

Transmission - Mechanical transmission

Mechanical transmission - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Gearbox Type of gears Reducer Type of gears Reduction ratio â&#x20AC;&#x201C; Idle Reduction ratio â&#x20AC;&#x201C; Middle Reduction ratio - Quick Gearbox and reducer control Thickness of the adjustment ring (5)* on the driven shaft of the gearbox Internal diameter of gears driven by the gearbox Outer diameter of bushings (17)* Clearance between the gears and bushings Diameter of the gearbox driven shaft (19)* Internal diameter of bushings (17)* Clearance between shaft and bushings Diameter of the Power Take-Off (PTO) clutch shaft (4)* Internal diameter of the installed bushing (1)* Clearance between the PTO gear shaft and the respective bushing Interference of installing the bushing on the driven shaft of the gearbox Detent balls springs (16) ** of the gearbox and reducer selector shafts - Length of spring without load Detent balls springs (16) ** of the gearbox and reducer selector shafts - Length of spring under load of 50 - 56 N ( 5.13 - 5.67 kgf Gearbox and reducer control lever detent springs - Length of spring Gearbox and reducer control lever detent springs - Length of spring under load of 94 104 N ( 9.6 - 10.6 kgf)

TL60E TL75E TL85E TL95E 4 speeds, constant mesh gears and synchronizers in all gears Helical teeth Cascade type with 3 forward speed ranges and 1 reverse speed range totaling 12 forward and 4 reverse speeds Straight-toothed 23 x 17 / 43 x 50 = 1:5.49 23 x 17 / 43 x 34 = 1:2.35 1 Independent, through manual levers located on the RH side of the operator 3.00 mm- 3.25 mm- 3.50 mm- 3.75 mm- 4.00 mm 50.050 49.925 0.100 39.175 39.200 0.009

50.075 mm 49.950 mm 0.150 mm 39.191 mm 39.239 mm 0.064 mm

24.979 - 25.000 mm 25.040 - 25.092 mm 0.40 - 0.113 mm 0.037 - 0.091 mm 30 mm (1.2 in)

25.5 mm (1.0 in) 75 mm (2.95 in) 42 mm (1.7 in)

* See the references in Mechanical transmission - Sectional view (21.114). ** See the references in Mechanical transmission - Sectional view (21.114).

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Transmission - Mechanical transmission

Mechanical transmission - Special tools TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

NOTICE: The operations described in this section should only be performed using the essential tools that appear below with the symbol "X". However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section.

293940 380000549

Use a splitting kit appropriate for the weight and sizes of the tractor Use a lifting hook appropriate for the weight and size of the component Use a rotating trestle appropriate for the weight and sizes of the component Front support Rear support Adapter to extract the pin from the reverse gear (with ) 292927 Sliding Hammer

Punch to be carried out in order to remove the controlled gearbox shaft (on tool mark No. 50006 - sizes in mm). Made from UNI C40 material.

LAIL11TL0453A0A

LAIL11TL0454A0A

Tool to use to adjust the bearings on the controlled gearbox shaft - sizes in mm. Made from Aq 45 material.

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Transmission - Mechanical transmission

LAIL11TL0974F0A

Tool to take apart the rear bearing from the controlled reducer shaft and from the controlled medium speed gear sizes in mm. Made from UNI C40 material. NOTE: Part no. 1 must be made with two examples.

Mechanical transmission - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Reference (C1) (C2) (C3) (C4) (C5)

Parts Bolts or nuts for fastening the clutch box/inverter and supplementary reducer to the engine Cover fixing nuts Nuts to fasten the cover of the rear transmission box/gearbox Bolts that fasten the covers of the bearings for the control and controlled shafts of the gearbox Lock nut on the controlled gear shaft

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Torque value 98 N·m (72.3 lb ft) 17 N·m (12.5 lb ft) 59 N·m (43.5 lb ft) 28 N·m (20.7 lb ft) 294 N·m (216.8 lb ft)

Transmission - Mechanical transmission

Reference (C6)

Parts Bolts for fastening the clutch box/inverter and supplementary reducer to the rear transmission box/gearbox

LAIL11TL1019G0A

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Torque value 98 NÂˇm (72.3 lb ft)

Transmission - Mechanical transmission

Mechanical transmission - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

LAIL11TL1025G0A

Longitudinal sections of gearbox and reducer

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Transmission - Mechanical transmission

Reference

Component

(11)

Lock half-rings

(2) (3)

Component Power Take-Off (PTO) shaft support bushing Sealant Gearbox drive shaft

(12) (13)

(4)

Power Take-Off (PTO) Shaft

(14)

(5) (6)

Drive shaft adjustment ring Reducer driven shaft

(15) (16)

(7)

Reverse and mid-range control gear

(17)

(8) (9) (10)

Top cover Mid-range driven gear Conical pinion shaft

(18) (19)

Controlled gear for reverse range Controlled gear for slow range Fast range and slow-range engagement collar Locking ring 1st and 2nd speeds hitch synchronizer Support bushings for gearbox controlled gears st nd 3 and 4 speeds hitch synchronizer Gearbox controlled shaft

Reference (1)

NOTE: During assembly, apply sealing anaerobic sealant LOCTITEÂŽ 515â&#x201E;˘ to surfaces (X) as described in Mechanical transmission - Service instruction (21.114).

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Transmission - Mechanical transmission

Cross sections of gearbox and reducer

LAIL11TL1098G0A

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Transmission - Mechanical transmission

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Reference Reducer control transmission rod Gearbox control transmission rod Slow and fast-range engagement rod Mid and reverse-range engagement rod Engagement rod for speeds 3 and 4 Engagement rod for speeds 1 and 2 Reducer driven shaft Idler gear for reverse range Mid and reverse-range control gear Mid-range driven gear

Reference (14) (15) (16) (17) (18) (19) (20) (21) (22) (23)

(11)

Intermediate gear pin (8) (reverse)

(24)

(12) (13)

Pin fastening bolt (11) Bearings

(25) (26)

Component Washer and fastening bolt (Allen) Top cover of transmission box/gearbox Spring Ball Gear control safety tab Plug Gear control safety tab Range control safety tab Plug Slow and fast-range engagement rod Reverse and mid-range engagement rod Engagement rod for speeds 3 and 4 Engagement rod for speeds 1 and 2

NOTE: The covers (19) and (22) must be screwed on with anaerobic sealant LOCTITEÂŽ 515â&#x201E;˘.

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Transmission - Mechanical transmission

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Transmission - Mechanical transmission

Longitudinal sections of gearbox and reducer

LAIL11TL1090H0A

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Transmission - Mechanical transmission

LAIL11TL1031G0A

Gear box cross-sections

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Transmission - Mechanical transmission

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Reverser/medium range selector shaft Slow/fast ranges selector shaft 1st and 2nd gears selector shaft Lock balls Spring for ball (4) Gears safety tab Spring for ball (8) Lock balls 3rd and 4th gears selector shaft

Reference (13) (14) (15) 16 (17) (18) (19) (20) (21)

(10)

External command lever for PTO

(22)

(11) (12)

Gear safety tab Plug

(23) (24)

Component Gears safety tab Plug Reverse gear support pin Reverse pin fixing bolt Reverse idler gear Axial bearing housing (bearing) Locking ring Power Take-Off (PTO) Shaft Reverser drive shaft Hitch gear of medium and reverse ranges. Medium range drive gear Locking ring

NOTE: Screw on the covers (12) and (14) with anaerobic sealant LOCTITEÂŽ 515â&#x201E;˘.

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Transmission - Mechanical transmission

Mechanical transmission - Service instruction TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

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Transmission - Mechanical transmission

CUIL13TR00527AA

Anaerobic sealant application on the transmission box diagram.

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Transmission - Mechanical transmission

Mechanical transmission - Remove - Machines with cab WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Front wheels - Remove (44.511) . Prior operation: Radiator - Drain fluid (10.400) . To remove the rear transmission box from the tractor, proceed as follows: 1. Disconnect the negative (â&#x2C6;&#x2019;) battery cable (1) from the battery. 2. Remove engine side shields. Consult the procedures in Side shield - Remove (90.102). 3. Remove the engine hood. Consult the procedures in Hood - Remove (90.100). 4. Remove cab from the tractor. Consult the procedures in Cab - Remove (90.150). 5. Drain the fuel from the fuel tank. Consult the procedures in Fuel tank - Drain fluid (10.216) .

CUIL13TRO0194AA

LAIL11TL0589A0A

6. Drain the fuel from the auxiliary fuel tank. Consult the procedures in Auxiliary fuel tank - Drain fluid (10.216). 7. Drain the oil from the transmission. Consult the procedures in Transmission housing - Drain fluid (21.114). 8. Remove the drive shaft for the Auxiliary Front Wheel Drive (AFWD). Consult the procedures in Drive shaft - Remove (23.314). 9. Disconnect hydraulic pump suction tubes (1) and transmission/gearbox tubes (2).

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Transmission - Mechanical transmission

10. Disconnect the electric connection (1). 11. Remove the bolts (2) and (4) and disconnect the ground wires.

LAIL11TL0590A0A

LAIL11TL0591A0A

LAIL11TL0593A0A

LAIL11TL0594A0A

12. Remove the bolts of the third point support (1) and remove the support together with the support plate (2). 13. Remove the remote control valve assembly. Consult the procedures in Remote control valve - Remove (35.204).

14. Loosen the bolts of the transmission box cover (1). 15. Lift the transmission box cover (1).

16. Loosen nut (2). 17. Remove the transmission box oil filling tube (1).

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Transmission - Mechanical transmission

18. Loosen nut (1). 19. Remove the electrohydraulic Power Take-Off (PTO) brake command line (2).

LAIL11TL0595A0A

LAIL11TL0596A0A

LAIL11TL0597A0A

20. Loosen the bolts securing the hydraulic lift. 21. Use a hook (1) with appropriate capacity to remove the hydraulic lift.

22. Loosen nut (2). 23. Remove the brake line (1). NOTE: Perform the procedure on the other side of the machine.

24. Loosen the clamp (1). 25. Remove the injection pump supply pipe (2). 26. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216).

LAIL11TL0598A0A

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Transmission - Mechanical transmission

27. Loosen nut (2). 28. Remove the electrohydraulic Power Take-Off (PTO) supply line (1). 29. Loosen the nut (3) and remove the PTO lubrication line (4).

LAIL11TL0603A0A

LAIL11TL0604A0A

LAIL11TL0605A0A

LAIL11TL0606A0A

30. Remove the electrical connections from the solenoids (1) and (3) that control the Auxiliary Front Wheel Drive (AFWD), the Power Take-Off (PTO), the differential lock and the front wheel drive pressure sensor. NOTE: Mark the electrical connections with the respective solenoids to facilitate installation.

31. Disconnect all the valve tubes with solenoid. 32. Remove the bolt (1). 33. Remove the lever (2) that deactivates the solenoid when the Power Take-Off (PTO) is synchronized with the transmission box.

34. Place one of the portable trolleys (1) of the tool 380000569 under the front section of the transmission box. 35. Position the other portable trolleys of the tool in the rear section of the transmission box.

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Transmission - Mechanical transmission

36. Position the fixed trolley (1) from the tractor splitting kit under the clutch box with a wooden block (3). 37. Loosen the fastening bolts and, if required, remove the rear wheels placing two fixed trestles under the ends of the side shafts.

LAIL11TL0607A0A

LAIL11TL0608A0A

LAIL11TL0609A0A

LAIL11TL0610A0A

38. Loosen the bolts (1) and remove the valve with solenoid valve from the transmission box.

39. Use a chain to attach the connection hook to the winch. 40. Loosen the bolts (1) and remove the trailer support (2).

41. Loosen nut (1). 42. Remove the bolt and the lower arms (3). 43. Remove the spacers (2).

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Transmission - Mechanical transmission

44. Loosen the bolt (1) and remove the cover (2).

LAIL11TL0611A0A

LAIL11TL0612A0A

LAIL11TL0613A0A

LAIL11TL0614A0A

45. Use a chain to attach the Power Take-Off (PTO) assembly (1) to the winch. 46. Loosen the fastening bolts and remove the rear shaft box assembly (2).

47. Attach a chain on the side casing of the assembly (1). 48. Loosen the nuts and remove assembly from the rear axle box. 49. Remove the splined ring gear (2) with the brake unit (3) and the friction disc (4).

50. Removing the friction disc (2) requires turning the differential electro-hydraulic lock control connection (1).

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Transmission - Mechanical transmission

51. Loosen the drain plug (2) and drain the oil from the flexion bar support. 52. Use a nylon rope to attach the end of the flexion bar (1) to the winch. 53. Loosen the fastening bolts and remove the complete assembly from the internal connection rod.

LAIL11TL0615A0A

LAIL11TL0616A0A

54. Attach the chain (1) on the transmission box (2). Connect the chain to the winch and apply tension on the chain. 55. Loosen the fixing bolts and remove the rear transmission.

Next operation: Mechanical transmission - Disassemble (21.114) .

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Transmission - Mechanical transmission

Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Disconnect the negative (â&#x2C6;&#x2019;) battery cable (1) from the battery. 2. Height of hood of the Rollover Protection Structure (ROPS). Consult the procedures in Roll Over Protective Structure (ROPS) frame canopy - Remove (90.114). 3. Remove the operating platform. Consult the procedures in Platform - Remove (90.110). 4. Drain the oil from the transmission. Consult the procedures in Transmission housing - Drain fluid (21.114). 5. Remove the Auxiliary Front Wheel Drive drive shaft. Consult the procedures in Drive shaft - Remove (23.314).

CUIL13TRO0194AA

LAIL11TL0589A0A

LAIL11TL0590A0A

6. Disconnect hydraulic pump suction tubes (1) and transmission/gearbox tubes (2).

7. Disconnect the electric connection (1). 8. Remove the bolts (2) and (4) and disconnect the ground wires.

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Transmission - Mechanical transmission

9. Remove the bolts of the third point support (1) and remove the support together with the support plate (2). 10. Remove the third point support with the support plate assembly (2). 11. Remove the remote control valve assembly. Consult the procedures in Remote control valve - Remove (35.204).

LAIL11TL0591A0A

LAIL11TL0593A0A

LAIL11TL0594A0A

LAIL11TL0596A0A

12. Loosen the bolts of the transmission box cover (1). 13. Lift the transmission box cover (1).

14. Loosen nut (2). 15. Remove the transmission box oil supply line (1).

16. Loosen the bolts securing the hydraulic lift. 17. Use an appropriate hook (1) to remove the hydraulic lift.

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Transmission - Mechanical transmission

18. Loosen nut (2). 19. Remove the brake line (1). NOTE: Perform the procedure on the other side of the machine.

LAIL11TL0597A0A

LAIL11TL0598A0A

20. Loosen the clamp (1). 21. Remove the injection pump supply pipe (2). 22. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216) .

23. Remove the nut (1) from the pressure tube of the control valve of the Auxiliary Front Wheel Drive (AFWD).

CUIL13TR00804AA

LAIL11TL0606A0A

24. Place one of the portable trolleys (1) from the tractor splitting kit under the front section of the transmission box. 25. Position the other portable trolleys from the tractor splitting kit for the rear section of the transmission box.

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Transmission - Mechanical transmission

26. Position the fixed trolley (1) from the tractor splitting kit under the clutch box with a wooden block (3). 27. Loosen the fastening bolts and, if required, remove the rear wheels placing two fixed trestles under the ends of the side shafts.

LAIL11TL0607A0A

LAIL11TL0609A0A

LAIL11TL0610A0A

LAIL11TL0611A0A

28. Use a chain to attach the connection hook to the winch. 29. Loosen the bolts (1) and remove the trailer support (2).

30. Loosen nut (1). 31. Remove the bolt and the lower arms (3). 32. Remove the spacers (2).

33. Loosen the bolt (1) and remove the cover (2).

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Transmission - Mechanical transmission

34. Use a chain to attach the Power Take-Off (PTO) assembly (1) to the winch. 35. Loosen the fastening bolts and remove the rear shaft box assembly (2).

LAIL11TL0612A0A

LAIL11TL0613A0A

LAIL11TL0615A0A

LAIL11TL0616A0A

36. Attach a chain on the side casing of the assembly (1). 37. Loosen the nuts and remove assembly from the rear axle box. 38. Remove the splined ring gear (2) with the brake unit (3) and the friction disc (4).

39. Loosen the drain plug (2) and drain the oil from the flexion bar support. 40. Use a nylon rope to attach the end of the flexion bar (1) to the winch. 41. Loosen the fastening bolts and remove the complete assembly from the internal connection rod.

42. Attach the chain (1) on the transmission box (2). Connect the chain to the winch and apply tension on the chain. 43. Loosen the fixing bolts and remove the rear transmission.

Next operation: Mechanical transmission - Disassemble (21.114) .

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Transmission - Mechanical transmission

Mechanical transmission - Disassemble Prior operation: Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform (21.114)

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Attach the transmission box on the rotating trestle using a support for the rear and another for the front.

LAIL11TL0647A0A

LAIL11TL0648A0A

LAIL11TL0649A0A

2. Turn the transmission box to 180 Â°. 3. Loosen the bolts (1) and remove the transfer box (2).

4. Turn the box to 180 Â°. 5. Use a punch to remove the spring pins (1) and remove the gearbox and selection shafts and forks for the final control. 6. Remove the differential from the transmission housing. Consult the procedures in Differential - Remove (27.106).

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Transmission - Mechanical transmission

7. Disassemble the spring pin (2) and remove the external lever (1) that controls the Power Take-Off (PTO) synchronized with the gearbox.

LAIL11TL0658A0A

LAIL11TL0655A0A

LAIL11TL0656A0A

LAIL11TL0657A0A

8. Remove the inner lever (2) complete with the spring (1) and the tab (3).

9. Unlock and loosen the driven shaft fixing nut (1).

10. Remove the rear lock ring (1) that fastens the bearing to the end of the drive shaft.

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Transmission - Mechanical transmission

11. Use a hammer and a copper punch (1) to remove the medium speeds gear (2) together with the respective bearings and hitch sleeves (3).

LAIL11TL0659A0A

LAIL11TL0660A0A

12. Remove the end of the drive shaft (1).

13. Remove the lock ring (1) which holds the bearing (2) on the gear box drive shaft.

LAIL11TL0661A0A

LAIL11TL0662A0A

14. Place the tool 50006 (2) on the drive shaft and use the extractor (1) to remove the drive shaft. 15. Remove the bearings, gears, and respective bushings.

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Transmission - Mechanical transmission

16. Unlock the washer securing the nut (1) and loosen the nut.

LAIL11TL0499A0A

LAIL11TL0500A0A

LAIL11TL0501A0A

LAIL11TL0502A0A

17. Bolt the adapter 293940 (2) on the pinion (3) and use the sliding hammer 380000549 (1) to move the pinion a few millimeters in the direction shown.

18. Move the engagement sleeve (1) until you are able to gain access with a pair of pliers (2) to remove the lock ring.

19. Move the gear (1) in the direction shown and remove the two locking semi-rings (2). 20. Loosen the nut (3) fully, remove the pinion, and disassemble all the parts.

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Transmission - Mechanical transmission

21. Loosen the bolts (3), remove the support plate (1) and remove the bearing (2).

LAIL11TL0503A0A

LAIL11TL0504A0A

22. Use a copper slug and a hammer to move the driven shaft (1). 23. Remove the shaft and disassemble all the parts. NOTE: Pay attention to the positioning of each gear when disassembling the shaft.

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Transmission - Mechanical transmission

Mechanical transmission - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Place the transmission in the vertical position. Mount the gear group of the driven shaft (2) and the shaft (1).

LAIL11TL0944B0A

LAIL11TL0505A0A

2. Turn the transmission at 90 Â°. Install the front bearing (1) and nut (2). Apply the torque described in Mechanical transmission - Torque (21.114).

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Transmission - Mechanical transmission

3. Mount the bearing (2) in its seat at the front end of the transmission. Lock the bearing using the plate (1).

LAIL11TL0506A0A

LAIL11TL0507A0A

LAIL11TL0508A0A

LAIL11TL0509A0A

4. Mount the forks (1) and (3) on the collars (2) and (4) of the synchronizers. 5. Mount the complete pinion with all the parts. Make the adjustments as described in Bevel pinion - Depth adjust (27.106) and Bevel pinion - Preload (27.106).

6. Mount the entire drive shaft with all the parts and the adjustment shim (3). 7. Position the bearing (2). 8. Lock the bearing using the lock ring (1).

9. Install the final drive shaft and position the bearing (2). 10. Lock the bearing using the lock ring (1). NOTE: To adjust the end play of the mid-range gear, insert the adjustment shim (2) between the bearing and the lock ring.

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Transmission - Mechanical transmission

11. Install the mechanism (internal lever, tab, spring, and external lever) (1) for engaging and disengaging the Power Take-Off (PTO) synchronized with the transmission. 12. Install the differential crown assembly with journals and shims. Make the adjustments as described in Differential - Gear tooth contact (27.106), Differential Install (27.106), Differential lock - Adjust (27.106), and Differential lock mechanical control - Adjust (27.106). 13. Install the complete mechanism of the differential lock. 14. Mount the selector shafts and the respective selector forks. 15. Install the transfer case assembly.

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LAIL11TL0510A0A

Transmission - Mechanical transmission

Mechanical transmission - Install - Machines with cab CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Before reinstalling the boxes, supports, and covers, clean out and thoroughly remove the material from the matching surfaces and apply a layer of Loctite of about 2 mm in diameter as shown in the diagram in Mechanical transmission - Service instruction (21.114). 2. Apply the torque recommended on Mechanical transmission - Torque (21.114) 3. Use an appropriate splitting kit to reinstall the rear transmission box on the clutch box. 4. Install the complete flexion bar support with the inner connection rod.

LAIL11TL0615A0A

LAIL11TL0614A0A

LAIL11TL0612A0A

5. Position the left-hand brake friction disc (2) and fasten it with the differential lock control union (1). Adjust the brake set, crown, and side casing set. 6. Install the right-hand brake friction disc, brake set, crown and side set.

7. Reinstall the Power Take-Off (PTO) assembly (1) in the transmission box (2). 8. Install the inner cover complete with the oil discharge tube. 9. Install the spacers and lower arms.

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Transmission - Mechanical transmission

10. Install the valve with solenoid support and connect all tubes between the support and the several services. 11. Connect the lever to switch off the solenoid when the PTO is synchronized with the gearbox. 12. Make the electrical connections between the respective solenoids and sensors. 13. Connect the control tubes for the PTO lubrication and PTO brake. 14. Install the fuel reservoir together with the fixing clamps and the supports. 15. Install the fuel reservoir tubes and connections. 16. Fully assemble the hydraulic lift with the control valve. 17. Install the service brake control tubes. 18. Install the remote control valve set. 19. Install the lock balls and springs and install the shift control rods support cover in the gear box. 20. Install and connect the lift control and the oil feed tubes. 21. Install the third point support with the quick hitch support and the electrical connections. 22. Fasten the electrical connections and the ground wire on the support plate and make the respective connections. 23. Install and connect the pressure tubes and the suction ones and install the tubes with the remote control valve, with the hydraulic lift, with the transfer box, etc. 24. Install the rear wheels and remove the tractor splitting kit. 25. Install the prop shaft for the Auxiliary Front Wheel Drive (AFWD) and fasten it to the central support and front and rear sleeves. 26. Install the prop shaft guard. 27. Bolt the oil drain plugs and fuel reservoir drain plug to the rear transmission box. 28. Place the cab onto the box and transmission and fasten with the fixing bolts. 29. Install the Lift-O-Maticâ&#x201E;˘ control cable. 30. Install the differential mechanic lock activation rod, if it exists. 31. Install the hand brake control cable. 32. Install the levers on the gear box. 33. Install the reverser control rod, if it exists. 34. Install the PTO rpm selection cable. 35. Install the connection rod of the PTO synchronized with the gearbox. 36. Install the remote control control levers.

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LAIL11TL0608A0A

Transmission - Mechanical transmission

37. Install the fuel reservoir and the vent tube on the rear transmission. 38. Install the hydraulic lift control rods. 39. If they exist, install the air conditioner system quick hitches; otherwise, readjust and fasten the compressor, condenser, and filter/dryer. Install and fasten the air filter piping or the connection tube to the turbo charger. Remake the electrical connections from the filter/dryer and sensor to the connection tube. 40. Install and fasten the heating control tubes. 41. Install the gear box clutch control rod. 42. Connect the warning and side lights. 43. Install the steering tubes. 44. Install the throttle control cable. 45. Install the service brake tubes to the respective cylinders and remake the electrical connections on the reservoir and pressure sensors. 46. Connect and fasten the rev-counter cable to the engine. 47. Make the electrical connections between the tractor cab and body. 48. Install and fasten the engine hood set. 49. Install and fasten the complete engine hood with the lifting shock absorbers. 50. Connect the front lights. 51. Bolt in the engine coolant drain plug. 52. Fill the fuel tank, rear transmission box, and cooling circuit with the recommended products and quantities. See the specification and capacity of fluids in Capacities () 53. Connect the negative battery cable.

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Transmission - Mechanical transmission

Mechanical transmission - Install â&#x20AC;&#x201C; Machines with platform DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Install the prop shaft for the Auxiliary Front Wheel Drive (AFWD) and fasten it to the central support and front and rear sleeves. 2. Install the prop shaft guard. 3. Bolt the oil drain plugs and fuel reservoir drain plug to the rear transmission box. 4. Place the cab onto the box and transmission and fasten with the fixing bolts. 5. Install the Lift-O-Maticâ&#x201E;˘ control cable. 6. Install the differential mechanic lock activation rod, if it exists. 7. Install the hand brake control cable. 8. Install the levers on the gear box. 9. Install the reverser control rod, if it exists. 10. Install the PTO rpm selection cable. 11. Install the connection rod of the PTO synchronized with the gearbox. 12. Install the remote control control levers. 13. Install the fuel reservoir and the vent tube on the rear transmission. 14. Install the hydraulic lift control rods. 15. If they exist, install the air conditioner system quick hitches; otherwise, readjust and fasten the compressor, condenser, and filter/dryer. Install and fasten the air filter piping or the connection tube to the turbo charger. Remake the electrical connections from the filter/dryer and sensor to the connection tube. 16. Install and fasten the heating control tubes. 17. Install the gear box clutch control rod. 18. Connect the warning and side lights. 19. Install the steering tubes. 20. Install the throttle control cable. 21. Install the service brake tubes to the respective cylinders and remake the electrical connections on the reservoir and pressure sensors. 22. Connect and fasten the rev-counter cable to the engine. 23. Make the electrical connections between the tractor cab and body. 24. Install and fasten the engine hood set.

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Transmission - Mechanical transmission

25. Install and fasten the complete engine hood with the lifting shock absorbers. 26. Connect the front lights. 27. Bolt in the engine coolant drain plug. 28. Fill the fuel tank, rear transmission box, and cooling circuit with the recommended products and quantities. See the specification and capacity of fluids in Capacities () 29. Connect the negative battery cable.

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Transmission - Mechanical transmission

Mechanical transmission - Adjust TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Gear drive shaft axial play adjustment After installing the drive shaft, the gears must have an axial play of 0 - 0.25 mm. The bearings must be adjusted to prevent them from being assembled with an axial pre-load. Carry out the following procedures: 1. On a bench, assemble the drive shaft components (1), such as gears, spacer bushes, bearings, and lock ring. NOTE: Do not install the adjustment shim (3) during this procedure.

LAIL11TL0511A0A

LAIL11TL0512A0A

2. Insert a screw driver between the gear and the spacer bushing and use a feeler gauge (3) to measure play (H). 3. The adjustment shim to be placed is determined by the formula S = H - A, where • S = Thickness of the adjustment shim • H = Measured play • A = Nominal play ( 0 - 0.25 mm)

Example: • Measured H play = 1.3 mm • Nominal play = 0 - 0.25 mm Thickness of adjustment ring: • S = 1.3 mm - 0.25 mm = 1.05 mm • S = 1.3 mm - 0 mm = 1.3 mm

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Transmission - Mechanical transmission

For the example given, the adjustment ring can have a thickness of 1.05 mm to 1.3 mm.

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Transmission - Mechanical transmission

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Range drive shaft axial play adjustment After installing the drive shaft, the mid-range gear (7) must have an axial play of 0 - 0.2 mm. The bearing (8) must be adjusted to allow for axial play of the gear (7), which helps lubricate the bearings. However, if the play is higher than 0.2 mm in many cases, the mid-range coupling sleeve/gear (6) disconnects while operating. Carry out the following procedures: 1. After assembling the top shaft of the ranges (5), check the axial play between the mid-range gear (7) and shaft (5).

LAIL11TL0513A0A

LAIL11TL0514A0A

2. With an appropriate tool (1), move the mid-range gear (2) backwards against the bearing. 3. Use a feeler gauge to measure the clearance between the gear (2) and the shaft (3).

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Transmission - Mechanical transmission

4. The adjustment shim (if required) to be placed between the bearing (2) and the lock ring (1) is determined by the formula S = H - A, where: • S = Thickness of the adjustment shim • H = Measured play • A = Nominal play ( 0 - 0.2 mm) Example: • Measured H play = 0.8 mm • Nominal play A = 0 - 0.2 mm Thickness of adjustment shim: S = 0.8 mm - 0.2 mm = 0.6 mm

LAIL11TL0515A0A

S = 0.8 mm - 0 mm = 0.8 mm For the example given, the adjustment shim can have a thickness of 0.6 mm to 0.8 mm.

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Transmission - Mechanical transmission

Transmission housing - Drain fluid Transmission Housing 1. Place a container with an adequate volume underneath the component, close to the fuel tank, and drain the oil using plugs (1) and (2). NOTE: Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

BRAG12TRLUE0519

BRAG12TRLUE0520

BRAG12TRLUE0521

Hydraulic system flexing bar 1. Place a container with an adequate volume underneath the component and drain the oil using the plug (1). NOTE: Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

Transfer box 1. Place a container with an adequate volume underneath the component and drain the oil using the plug (1). NOTE: Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

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Transmission - Mechanical transmission

Transmission housing - Filling 1. Park the machine on a level and hard surface. 2. Add lubricant oil to the maximum mark. Use the filler neck (1). NOTE: Do not add lubricant oil past the maximum “MAX” level. Do not start the engine when the oil level is below the minimum “MIN” marking. 3. Reinsert the dipstick into the filler neck. 4. See the specification and capacity of fluids in Capacities (). CUIL13TR00524AA

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Index Transmission - 21 Mechanical transmission - 114

(*)

Mechanical transmission - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Install - Machines with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Install â&#x20AC;&#x201C; Machines with platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Remove - Machines with cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Mechanical transmission - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission housing - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Transmission housing - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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Transmission - 21 Creeper - 160

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Contents Transmission - 21 Creeper - 160

TECHNICAL DATA Creeper General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Creeper Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Creeper Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DIAGNOSTIC Creeper Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™

Reference Creeper - Sectional view Creeper - Assemble

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PAGE 21.2 / 8 21.2 / 19

Transmission - Creeper

Creeper - General specification TL75E TL85E TL95E Cascade with spur gear placed between the engine clutch and gearbox, in series with the inverter. It allows the use of 20 forward gears and 12 reverse gears. 18x26 / 55x47 = 1:5.524 By a lever located to the left of the operator

Type

Reduction ratio Command

Creeper - Special tools Special tools NOTICE: Important - The operations described in this section should only be performed using the ESSENTIAL tools that appear below with the symbol "X". However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section. 299000

Tractor splitting kit Consists of 299001, 299002, 299003 Use a lifting hook appropriate for the weight and size of the component Use a rotating trestle appropriate for the weight and sizes of the component Front support Rear support

Compressor for assembling the gearbox-powered shaft retainer (Dimensions in mm).

CUIL13TR00796AA

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Transmission - Creeper

CUIL13TR00797AA

Tool to assemble the retainer on the gearbox controlled shaft Dimensions in mm - Material UNI 40

Creeper - Torque Reference (C1) (C2) (C3) (C4)

(C5)

Parts Bolts or nuts for fastening the clutch box/supplementary inverter and reducer to the engine Nuts for fastening the sleeve cover Nuts for fastening the supplementary inverter and reducer controlled shaft cover. Bolts that fasten the covers of the bearings for the control and controlled shafts of the gearbox Bolts for fastening the clutch box/inverter and supplementary reducer to the rear transmission box/gearbox

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Torque value 98 N·m (72 lb ft) 17 N·m (13 lb ft) 17 N·m (13 lb ft) 28 N·m (21 lb ft)

98 N·m (72 lb ft)

Transmission - Creeper

LAIL11TL1021G0A

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Transmission - Creeper

Creeper - Sectional view Longitudinal section of the supplementary inverter-reducer

LAIL11TL1023G0A

Component Supplementary inverter and reducer control shaft

Reference

Component

(6)

Camshaft control gear - gearbox

(2)

Retainer

(7)

(3) (4)

Locking ring Supplementary reducer control gear Supplementary control synchronizer for the inverter-reducer

(8) (9)

Supplementary reducer controlled gear Thrust shim Inverter controlled shaft

(10)

Bearing

Reference (1)

(5)

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Transmission - Creeper

Creeper - Sectional view

LAIL11TL1024G0A

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Inverter control fork Ball Inverter control synchronizer Sealant Inverter external control lever Supplementary reducer control fork Ball Supplementary reducer external control lever Sealant Supplementary reducer control gear

Reference (11) (12) (13) (14) (15) (16) (17) (18) (19) (20)

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Component Inverter idler gear Needle bearing Gear pin (11) Sealant Pin fastening bolt (13) High gear lock latch Supplementary inverter and reducer control rod Inverter control synchronizer Supplementary reducer control gear Rod retaining bolt (17) (apply to bolt LOCTITEÂŽ 515â&#x201E;˘)

Transmission - Creeper

Creeper - Dynamic description Description and operation The supplementary inverter-reducer group is a mechanical device that gives the possibility to have 20 forward gears and 12 reverse gears. The supplementary reducer intervenes only in slow and medium ranges. A mechanical lock prevents its introduction in the fast range. The supplementary reducer is composed of a group of three spur gears: a control sliding gear, a synchroniser control gear, and a controlled gear which is the same as the inverter. The supplementary reducer assembled in series to the inverter and is controlled by an adequate manual lever placed on the operator's right side. The inverter is made up of a group of three gears with spur gears: an inverter control gear, an idler gear and an inverter controlled gear. The hitch mount is done though a synchronizer placed in the gear assembly. The supplementary inverter-reducer group is assembled inside the clutch box between the clutch and the gearbox. Lubrication is ensured by the oil contained in the transmission box.

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Transmission - Creeper

Creeper - Sectional view Longitudinal section of the supplementary inverter and reducer

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Transmission - Creeper

BRAG12TR0075LUE

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Transmission - Creeper

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Transmission - Creeper

Creeper - Disassemble Prior operation: Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform (21.114)

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Place the transmission box on the rotating trestle using a support for the rear and another for the front.

LAIL11TL0446A0A

LAIL11TL0447A0A

LAIL11TL0448A0A

2. Remove the lock ring (1) and the gear (2).

3. Remove the lock ring (1).

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Transmission - Creeper

4. Remove the cap (1).

LAIL11TL0451A0A

LAIL11TL0452A0A

LAIL11TL0449A0A

LAIL11TL0450A0A

5. Remove the synchronizer group (1) along with the gear control forks.

6. Remove the gear (1) along with the needle bearings, then remove the thrust washer.

7. Remove the springs (2) and the clutch collar (1) assembly (1).

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Transmission - Creeper

8. Loosen the fastening bolts (2) and remove the control forks (1).

LAIL11TL0436A0A

LAIL11TL0437A0A

9. Remove the fastening bolt from the pin and extract the gear group for the inverter idler (1).

10. Loosen the fastening bolts and remove the cover (1).

LAIL11TL0438A0A

LAIL11TL0439A0A

11. Tap on the rear side to remove the shaft (1) together with its bearing.

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Transmission - Creeper

12. Loosen the fastening bolts and remove the cover-support (1).

LAIL11TL0440A0A

LAIL11TL0441A0A

LAIL11TL0442A0A

LAIL11TL0443A0A

13. Remove the lock ring (2), then remove the whole shaft (1) with the bearing.

14. Remove the lock ring (1).

15. Remove the retainer (1) using a suitable tool.

Next operation: Creeper - Assemble (21.160) .

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Transmission - Creeper

Creeper - Assemble Prior operation: Creeper - Disassemble (21.160) .

Install the supplementary inverter and reducer CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Assemble all the supplementary inverter and reducer parts in their box, taking the following into account. 2. Follow the illustrations presented in Creeper - Sectional view (21.160) and Creeper - Sectional view (21.160) for the orientation of the various components. 3. Observe the tightening torques indicated in Creeper Torque (21.160). 4. Assemble the lock ring (1) in its housing.

LAIL11TL0442A0A

LAIL11TL0444A0A

5. Use the tools (4) and (5) according to the measures described in Creeper - Special tools (21.160). 6. Assemble the bar (3) on the clutch box, insert the installation rod (4) in the housing with the retainer in contact with the lock ring (1), figure 1.

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Transmission - Creeper

7. Tighten the nut (1) until a distance (H) of 3,3 - 3,6 mm is reached between the bar and nut, then lock the nut using the locknut (5). NOTE: Leave the rod (1) with the nut placed like this when you also finish carrying out the replacement. In future replacements, only check if the distance (H) is as indicated. 8. Remove the rod (1), the bar (2) and the lock ring (1), figure 1. 9. Insert the new retainer in its housing.

LAIL11TL0444A0A

LAIL11TL0445A0A

LAIL11TL0441A0A

LAIL11TL0440A0A

10. Reassemble the bar (2) on the clutch box, and insert the rod (1) in the bar. 11. Insert the retainer until the nut (1), figure 3, reaches the limit against the bar (2). 12. Remove the bar (2) and remove the rod (1).

13. Assemble the whole control shaft with the bearing and fastening lock rings (2).

14. Assemble and secure the cover-support (1). 15. Assemble the supplementary inverter and reducer controlled gear shaft. 16. Assemble the cover for the controlled gear shaft and secure it with the appropriate bolts. 17. Assemble the inverter idler gear group and secure it with its bolt.

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Transmission - Creeper

18. Assemble and lock the clutch control forks (1) to their respective levers. 19. Assemble the clutches collars and lock them using their respective locks. 20. Assemble the whole controlled gear with bearing and thrust washer.

LAIL11TL0436A0A

LAIL11TL0449A0A

LAIL11TL0446A0A

21. Assemble the whole synchronizer group (1), all the gears and control forks, then fasten them with their respective lock ring. 22. Assemble the rod fixing screw coated with LOCTITEÂŽ 515â&#x201E;˘. 23. Assemble the gear on the inverter controlled shaft and lock it with its lock ring.

24. Remove the transmission box from the rotating trestle.

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Transmission - Creeper

Creeper - Troubleshooting Problem Difficult to engage the supplementary inverter-reducer group.

High noise level of the supplementary inverter-reducer group Spontaneous disengagement of the supplementary inverter-reducer group

Possible Cause Correction Wrong adjustment of the outer levers and Adjust properly rods Hardening and/or seizing of levers and rod Check joints and lubricate them connections Dragging of main clutch Please see Clutch - Sectional view (18.110) Remove the clutch box - gearbox and reSynchronizer fault place the synchronizer Difficulty sliding the internal controls: rods, Check the controls forks and sleeves Wear or damage of some internal compo- Remove the clutch box and replace damaged parts nent Wrong adjustment of the outer levers and Adjust properly rods

Failure of the synchronizer engagement Remove the transmission box and replace the synchronizer. gears Incomplete engagement travel. Eliminate the causes and re-establish full travel

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Index Transmission - 21 Creeper - 160 Creeper - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Creeper - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Transmission - 21 Reverser - 162

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Contents Transmission - 21 Reverser - 162

TECHNICAL DATA Reverser General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Reverser Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Reverser Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

DIAGNOSTIC Reverser Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

(*) See content for specific models 47835583 21/10/2015

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™ Loctite® 515™

Reference Reverser - Sectional view Reverser - Sectional view Reverser - Assemble

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Transmission - Reverser

Reverser - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

TL75E TL85E TL95E Mechanical with spur gears placed between the main clutch and gearbox. It consists of 1 control gear, 1 idler gear, and 1 transmission gear By hand lever located to the left of the operator

Type Command

Reverser - Special tools TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

NOTICE: Important - The operations described in this section should only be performed using the ESSENTIAL tools that appear below with the symbol "X". However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section. 299000

Tractor splitting kit Consists of 299001, 299002 and 299003 Use a lifting hook appropriate for the weight and sizes of the component. Use a rotating trestle appropriate for the weight and sizes of the component. Use a front support for the transmission box assembly Use a rear support for the transmission box assembly

Reverser - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

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Transmission - Reverser

Reference (C1) (C2) (C3) (C4) (C5)

Parts Bolts or nuts for fastening the clutch box/inverter to the engine Cover fixing nuts Nuts for fastening the cover to the controlled shaft support of the inverter Bolts for fastening the plate of the controlled shaft of the inverter Bolts for fastening the clutch box/inverter to the rear transmission box/gearbox

LAIL11TL1092G0A

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Turnbuckle

Torque value

M12 x 1.25

98 N·m (72 lb ft)

M8 X 1.25

17 N·m (13 lb ft)

M8 X 1.25

28 N·m (21 lb ft)

M10 X 1.25

64 N·m (47.2 lb ft)

M12 x 1.25

98 N·m (72 lb ft)

Transmission - Reverser

Reverser - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Longitudinal section of the inverter

LAIL11TL0973F0A

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

Component Inverter control shaft Retainer Roller bearings Inverter controlled gear Roller bearings

Reference (6) (7) (8) (9) (10)

NOTE: During assembly, apply LOCTITE® 515™ to the surface (X).

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Component Inverter control synchronizer Retainer Inverter control gear Controlled gear shaft (8) Seal

Transmission - Reverser

Reverser - Sectional view

LAIL11TL1020G0A

Reference (1) (2)

Component Inverter control fork Inverter control synchronizer

Reference (10) (11)

(3)

Inverter external control lever

(12)

(4) (5) (6) (7) (8) (9)

Seal Locking ring Thrust Washer Inverter transmission gear Roller bearings Thrust Washer

(13) (14) (15) (16) (17) (18) (19)

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Component Seal Transmission gear pin (7) Fixation plate of the pins ( (11) and (13)) Inverter control gear pin Inverter control rod Spacer Inverter control synchronizer Ball Spring for ball (17) Ball spring fastening bolt (the bolt should be installed with LOCTITEÂŽ 515â&#x201E;˘

Transmission - Reverser

Reverser - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Description and operation The inverter is a mechanical device that makes it possible to have 12 forward gears and 12 reverse gears, and is controlled by a specific lever on the cab platform to the left of the operator. The inverter is made up of a group of three gears with spur gears: inverter control gear, idler gear and inverter commanded gear. By a synchronizer placed in group of gears. The inverter is mounted inside the gearbox itself between the clutch and gearbox. Lubrication is ensured by the oil contained in the rear transmission box for onward transfer/gearbox.

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Transmission - Reverser

Longitudinal section of the transmission with inverter, double disc clutch, and PTO with mechanical control

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Transmission - Reverser

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Transmission - Reverser

BRAG12TR0074LUE

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Transmission - Reverser

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Transmission - Reverser

Reverser - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform (21.114)

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Place the inverter/clutch box (1) on the rotating trestle (2) using one support for the rear and another for the front.

LAIL11TL0425A0A

LAIL11TL0426A0A

2. Remove the fastening spring pin and remove the transmission lever (1) and the internal lever (2).

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Transmission - Reverser

3. Loosen the bolt (1)and remove the spring and ball.

LAIL11TL0427A0A

LAIL11TL0429A0A

LAIL11TL0430A0A

LAIL11TL0435A0A

4. Remove the lock ring (1) and remove the bearing, thrust washers, synchronizer group next to the control fork and the related rod, the inverter control gear (2) with its roller bearings and spacer.

5. Remove the inverter control gear (1) with its roller bearings.

6. Remove the lock ring (1) from the inverter control shaft.

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Transmission - Reverser

7. From the front of the clutch box/inverter and using an aluminum punch (2), extract the inverter control shaft (1) by removing it from the rear side of the box.

LAIL11TL0428A0A

LAIL11TL0431A0A

LAIL11TL0432A0A

8. Disengage the fastening springs and remove the sleeves from the clutch collars (1).

9. Loosen the fastening bolts and remove the sleeve cover-support (1).

10. Loosen the two bolts (1) securing the control forks of the clutch collar sleeves (2).

LAIL11TL0433A0A

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Transmission - Reverser

11. Remove the external shafts (1) of the clutch control (2) and remove the forks.

LAIL11TL0434A0A

LAIL11TL0424A0A

12. Release the latch and loosen the bolt (1) securing the mounting plate of the inverter control shaft pin (2) and the idler gear pin, removing them from the rear of the box.

Next operation: Reverser - Assemble (21.162)

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Transmission - Reverser

Reverser - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Reverser - Disassemble (21.162) . 1. Assemble the inverter considering the following: 2. Follow the illustrations as shown in Reverser - Sectional view (21.162) for the orientation of the various components. 3. Observe the tightening torques indicated in Reverser Torque (21.162). 4. Assemble the idler gear pin, complete from the various pieces, and the inverter's control gear pin and secure it through the appropriate plate and its bolt. 5. Assemble the control forks (2) of the clutch collar sleeves on the respective clutch control shafts and secure them to these. 6. Assemble the cover support of the sleeves on the clutch collars. 7. Assemble the group of clutch collar sleeves on the related support and fasten it with the appropriate springs.

LAIL11TL0434A0A

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Transmission - Reverser

8. Mount the inverter control shaft on the rear side and attach it to the clutch box/inverter with its respective lock ring.

LAIL11TL0428A0A

LAIL11TL0435A0A

LAIL11TL0430A0A

LAIL11TL0425A0A

9. Attach the shaft to the clutch box/inverter with the respective lock ring (1).

10. Place the inverter control gear (1) with its bearings on the control shaft. 11. Assemble the inverter's driven gear with its bearings and spacers. 12. Assemble the synchronizer group with its control forks, rod, thrust washer and bearing, and lock it with its respective lock ring. 13. Assemble the ball, spring and fastening bolt with LOCTITE® 515™. 14. Set the internal lever in place and assemble the transmission lever and secure it with its roll pin. 15. Take the inverter/clutch box off the rotating trestle (2).

Next operation: Mechanical transmission - Install – Machines with platform (21.114)

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Transmission - Reverser

Reverser - Troubleshooting Problem Spontaneous trip of the inverter

Inverter's engagement is difficult.

Possible Cause Wrong adjustment of external levers

Damage to the teeth of the syncronizer Remove the transmission box and replace the synchronizer. gear Incomplete engagement travel. Eliminate the causes and re-establish full travel Adjust properly Wrong adjustment of external levers Hardening and/or seizing of levers Dragging of main clutch Synchronizer fault

High noise level of the inverter

Correction Adjust properly

Check joints and lubricate them Refer Clutch - Sectional view (18.110). Remove the transmission box and replace the synchronizer. Difficulty sliding the internal controls: rods, Check the controls forks and sleeves Wear or defect in some internal component Remove the transmission box and replace damaged parts

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Index Transmission - 21 Reverser - 162

(*)

Reverser - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Reverser - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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

47835583 21/10/2015 EN

SERVICE MANUAL Four-Wheel Drive (4WD) system TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015

Contents Four-Wheel Drive (4WD) system - 23

[23.202] Electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.1 [23.304] Four-Wheel Drive (4WD) gearbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.2 [23.314] Drive shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23.3

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Contents Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

TECHNICAL DATA Electro-hydraulic control Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Electro-hydraulic control Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Front-Wheel Drive (FWD) control valve Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Front-Wheel Drive (FWD) control valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

(*) See content for specific models 47835583 21/10/2015

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - Special tools NOTE: Important - The operations described in this section should only be performed using the ESSENTIAL tools that appear below with the symbol "X". However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section. X

380000552

Pressure Gauge 0 - 40 bar

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Electro-hydraulic control - Component identification (1) . Valve solenoid responsible for the engagement/disengagement of the Auxiliary Front Wheel Drive (FWD). With the solenoid de-energized, the drive remains on through the action of the spring that keeps the sleeves coupled. On disconnecting the FWD, the solenoid is energized, and the flow of oil is routed to the mechanism through the tube (3), moving the sleeve to the front. (2) . Switch that turns on/off the warning light for the auxiliary front wheel drive on the instrument panel. (3) . Feed tube for the transfer box. (4) . FWD transfer box.

CUIL13TR00804AA

CUIL13TR00790AA

(5) . Oil inlet connection on the control valve, from the hydrostatic steering unit. (1) . 16.0 - 17.0 bar (232.0 - 246.5 psi) pressure regulating valve.

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Overview TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA ---

BRAG12TR2103

Reference (1) (2) (3)

Component Upper mounting Oil outlet to the Auxiliary Front-Wheel Drive (AFWD) transfer case Central mounting

Reference (4)

Component Banjo bolt

(5)

Supply of oil from the pump

(6)

Solenoid

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Pressure test CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

CAUTION Equipment rolling hazard! 1. Disengage all drives. 2. Engage parking brake. 3. Lower all attachments to the ground, or raise and engage all safety locks. 4. Shut off engine. 5. Remove key from key switch. 6. Switch off battery key, if installed. 7. Wait for all machine movement to stop. Failure to comply could result in minor or moderate injury. C0096A

Before performing hydraulic adjustments and tests: • Analyze and understand the hydraulic flow of the different functions and circuits. • Make sure that the oil level is correct. • Make sure of the correct specification of oil used. • Make sure that the system's oil filter is in good condition. If necessary, replace the filter. NOTE: All tests and adjustments must be conducted with an oil temperature of at least 50.0 °C (122.0 °F).

Testing the pressure regulating valve 1. Park the machine on a level and hard surface. 2. Install a "T" connection between the tube (1) and the port (3). 3. Install the pressure gauge 380000552 with a pressure scale between 0.0 - 40.0 bar (0.0 - 580.0 psi) on the "T" connection. 4. Start the engine. 1500 RPM.

Adjust the engine speed to

5. Make sure that the FWD is engaged. The solenoid (2) will be de-energized. 6. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi).

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CUIL13TR00804AA

Four-Wheel Drive (4WD) system - Electro-hydraulic control

7. If the pressure is incorrect, replace the pressure regulating valve (1). 8. If the pressure is correct, proceed with the leak tests below.

CUIL13TR00790AA

CUIL13TR00804AA

Leak test of the drive mechanism of the auxiliary front wheel With the pressure gauge still installed, perform the following procedures: 1. Make sure that the Auxiliary Front Wheel Drive (FWD) is disengaged. The solenoid (2) will be energized. 2. The pressure gauge should read 16.0 - 17.0 bar (232.0 - 246.5 psi). 3. If the pressure is incorrect, service the drive system of the FWD. Seek to eliminate likely pressure leaks through the seals or wear on the coupling and uncoupling sleeve, inside the transfer box. Consult the procedures in Four-Wheel Drive (4WD) gearbox - Remove (23.304). 4. If the pressure is correct, this means that there is no issue with the hydraulic circuit examined in the recent tests. Disconnect the pressure gauge 380000552 from the "T". 5. Remove the "T" from between the tube (1) and the port (3).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Remove Prior operation: Transmission housing - Drain fluid (21.114) 1. Disconnect the negative (-) cable (1) from the battery. 2. Drain the fuel from the fuel tank. Consult the procedures in Fuel tank - Drain fluid (10.216). 3. Put shims on the tractor's front wheels. 4. Remove the rear left wheel.

CUIL13TRO0194AA

LAIL11TL1091A0A

CUIL13TR00804AA

5. Disassemble the clamp (1) and separate the injection pump feed tube (2). 6. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216).

7. Remove the nut (5) and remove the pressure tube (1) for the control valve. NOTE: Fit a cover on each end of the tube. 8. Remove the nut (4) from the Auxiliary Front-Wheel Drive (AFWD) transfer case tube. NOTE: Fit a cover on each end of the tube. 9. Remove the banjo bolt (3). 10. Remove the top mounting bolt (X). Remove the Auxiliary Front-Wheel Drive (AFWD) control valve.

Next operation: Front-Wheel Drive (FWD) control valve - Install (23.202).

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Four-Wheel Drive (4WD) system - Electro-hydraulic control

Front-Wheel Drive (FWD) control valve - Install Prior operation: Front-Wheel Drive (FWD) control valve - Remove (23.202). 1. Install the Auxiliary Front-Wheel Drive (AFWD) control valve in the transmission housing. Secure the valve with the bolt (2). 2. Install the banjo bolt (3). 3. Install the Auxiliary Front-Wheel Drive (AFWD) transfer case tube. Attach the tube with the nut (4). 4. Install the pressure tube (1) for the control valve. Secure the tube with the nut (5). 5. Install the fuel tank. Consult the procedures in Fuel tank - Install (10.216). CUIL13TR00804AA

LAIL11TL1091A0A

6. Assemble the feed tube (2) for the injection pump. 7. Install the rear left wheel. 8. Connect the negative battery cable.

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Index Four-Wheel Drive (4WD) system - 23 Electro-hydraulic control - 202

(*)

Electro-hydraulic control - Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Electro-hydraulic control - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front-Wheel Drive (FWD) control valve - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front-Wheel Drive (FWD) control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front-Wheel Drive (FWD) control valve - Overview (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front-Wheel Drive (FWD) control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

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Contents Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304

TECHNICAL DATA Four-Wheel Drive (4WD) gearbox General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Four-Wheel Drive (4WD) gearbox Four-Wheel Drive (4WD) gearbox - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Four-Wheel Drive (4WD) gearbox - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Four-Wheel Drive (4WD) gearbox Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

DIAGNOSTIC Four-Wheel Drive (4WD) gearbox Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - General specification TL60E TL75E TL85E TL95E Transmission Ratio 34/34 = 1:1 Number of movable friction discs (14)* with one 2 face Number of movable friction discs (14)* with two 3 faces Number of hand brake discs (12)* 3 Diameter of the control lever pin for the hand 27.979 - 28.000 mm brake (16)* Diameter of the pin housing for the brake control 28.020 - 28.053 mm lever in the box (29)* Clearance between the pin (16)* and the housing 0.020 - 0.074 mm in the box (29)* Internal piston diameter (19)* 35.080 - 35.119 mm Coupled shaft diameter (1)* 35.002 - 35.027 mm Internal piston diameter (19)* 50.080 - 50.119 mm Coupled shaft diameter (1) 49.975 - 50.000 mm Inner fixed sleeve diameter (8) 38.050 - 38.089 mm Coupled shaft diameter (1)* 37.925 - 37.950 mm Length of spring (7)* without load 82 mm Length of spring (7)* with a load of 60.5 - 65.5 kg 40 mm Thickness of one-face disk (14)* 3.1 - 3.4 mm Thickness of two-face disk (14)* 4.2 - 4.5 mm Thickness of disc (12)* 3.95 - 4.05 mm Thickness of the washers (32) for adjusting the 1.5 mm - 1.9 mm - 2.2 mm - 2.5 mm - 2.8 mm - 3 mm - 3.3 mm clearance in the front sleeve (31)* of the Cardan - 3.7 mm - 4 mm - 4.3 mm shaft Axial clearance (L)* of the front sleeve 1.0 - 1.5 mm (*) See the references in Four-Wheel Drive (4WD) gearbox - Sectional view (23.304).

Four-Wheel Drive (4WD) gearbox - Special tools NOTICE: The operations described in this section should only be performed using the ESSENTIAL tools that appear below with the symbol (X). However, for greater safety and to obtain the best results, saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. 380000279 380000280

Protection for fitting the retainer with diameter 50 mm for the shaft. Protection for fitting the retainer with diameter 35 mm for the shaft.

Punch to be built for assembling/disassembling the transmission shaft disengagement spring. (No. 50107 should be inscribed on the tool). (Values in mm) NOTE: Build the tool with the material F42.

LAIL11TL0471A0A

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Torque

LAIL11TL0976F0A

Reference (C1) (C2) (C3) (C4) (C5)

Components Fixing bolt for the center support of the Cardan shaft Axial fixing bolt for the hand brake control lever Bolt with guide pin for the brake disks Fixing bolt for the transmission shaft Oil inlet connection for the piston Bolts for securing the transfer box to the transmission box

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Torque value 88 N·m (65 lb ft) 44 N·m (32 lb ft) 44 N·m (32 lb ft) 98 N·m (72 lb ft) 49 N·m (36 lb ft) 98.0 N·m (72.3 lb ft)

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Sectional view

LAIL11TL1027G0A

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13)

Component Driven shaft Dust cover ring Retainer Union ring Retaining lock ring Ball bearing Transfer box connecting spring. Fixed sleeve Needle bearing pin Idler gear Needle bearing Hand brake disks Ball bearings

Reference (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28) (29) (30)

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Component Driven Gear Piston Plate Retaining lock ring Oil supply connection for the piston O-ring seals O-ring seals Metal sealing rings O-ring seals O-ring seals Lever retaining bolt (16) Transfer box Retaining lock ring

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Reference (14) (15) (16) (17)

Component Brake devices O-ring seals Hand brake control lever Splined thrust washer

Reference (31) (32) (33) (L)

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Component Front sleeve with fitting Washers for adjusting the clearance (L) Retaining lock ring Sleeve axial clearance (31)

Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Dynamic description

LAIL11TL0977F0A

(1): Pressurized oil (2): Pressure-free oil The transfer box is mounted on the rear transmission box and is driven by the pinion shaft by a gear. The movement is transmitted to the front shaft through the Cardan shaft which connects the two units. The Auxiliary Front Wheel Drive (FWD) is engaged electrohydraulically when you turn on the switch on the control panel. When you turn on the switch, it cuts the electric current flow and the solenoid remains deactivated, without supplying oil to the piston's inner chamber (19)*, and parts (8)* and (19)* remain connected by the force of the spring. (7)*.The oil is drained from the control circuit, as shown in the figure above. The Auxiliary Front Wheel Drive (FWD) is disengaged electrohydraulically when you turn off the switch on the control panel. The control panel sends a signal to the relay which in turn energizes the solenoid. When the solenoid is energized, it drives the oil supply to the piston (19)*, and the FWD remains disengaged. The lubrication is done by the rear transmission box oil. (*) See the references in Four-Wheel Drive (4WD) gearbox - Sectional view (23.304).

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Proceed as follows: 1. Remove the negative (-) cable (1) from the battery. 2. Remove the drive shaft for the Auxiliary Front Wheel Drive (FWD). Consult the procedures in Drive shaft Remove (23.314). 3. Remove the fuel tank. See the procedures in Fuel tank - Remove (10.216). 4. Drain the oil from the transmission. Consult the procedures in Transmission housing - Drain fluid (21.114).

CUIL13TRO0194AA

CUIL13TR00774AA

LAIL11TL0458A0A

5. Remove the feed tube (2) for the FWD transfer box by loosening the respective bolts. 6. Remove the banjo bolt (1).

7. Remove the return spring (1) for the hand brake. 8. Remove the pin and roller (2). 9. Remove the nuts (3) and (5). Remove the lubrication tube (4) .

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

10. Place a hydraulic jack under the transfer box (1). 11. Remove the bolts (2) that fasten the transfer box to the gear box. remove the transfer box.

LAIL11TL0459A0A

Next operation: Four-Wheel Drive (4WD) gearbox - Disassemble (23.304)

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Disassemble Prior operation: Four-Wheel Drive (4WD) gearbox - Remove (23.304).

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Use the special punch to remove the spring pin (2). Then remove the pin (1). 2. Remove the needle bearing, the spacer, the support washers and the gear (3).

LAIL11TL0460A0A

CUIL13TR00799AA

LAIL11TL0461A0A

3. Remove the axial fixing bolt (1) for the parking brake control lever. 4. Use a special punch and remove the spring pin. 5. Remove the parking brake control lever.

6. Use a screwdriver to remove the dust cover ring (1).

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

7. Remove the retainer (1).

LAIL11TL0462A0A

LAIL11TL0463A0A

LAIL11TL0464A0A

LAIL11TL0465A0A

8. Remove the oil distribution connection (1) for disengagement of the auxiliary front wheel drive (AFWD).

9. Use a special punch to remove the oil flow manifold (1).

10. Remove the lock ring (1). Then remove the whole shaft (2). 11. Remove the hand brake disks, the driven gear, the fixed sleeve and the thrust washer.

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

12. Remove the two bolts (1) with the respective brake disk guide pins. 13. Remove the brake disks and the rear bearing.

LAIL11TL0466A0A

LAIL11TL0467A0A

14. Remove the control level (2) for the parking brake and the O-ring (1).

15. Place the drive shaft (1) in a hydraulic press and fasten the bearing (2) on a universal extractor, as shown in the diagram. 16. Activate the press and remove the bearing (2).

LAIL11TL0468A0A

LAIL11TL0469A0A

17. Rotate the driven shaft half a turn. Then place the driven shaft in the press as shown in the diagram. 18. Position the adapter (1) on the shaft. 19. Activate the press to compress the spring (4) and remove the lock ring (2). 20. Remove the plate (3), spring (4) and piston (5).

Next operation: Four-Wheel Drive (4WD) gearbox - Assemble (23.304).

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Assemble Prior operation: Four-Wheel Drive (4WD) gearbox - Disassemble (23.304) . 1. To assemble all of the parts that make up the transfer box, follow the procedures in reverse order described in Four-Wheel Drive (4WD) gearbox - Disassemble (23.304). 2. Check all the parts and replace any that are worn. 3. Check all the seals and replace them if necessary. 4. Use the tool 380000279 to position the O-ring seal (1) on the seat of the driven shaft. 5. Use the tool 380000280 (2) to position the O-ring seal (3) on the seat of the driven shaft. 6. Tighten the fixing bolts according to the torque values specified in Four-Wheel Drive (4WD) gearbox Torque (23.304).

CUIL13TR00800AA

Next operation: Four-Wheel Drive (4WD) gearbox - Install (23.304) .

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Install Prior operation: Four-Wheel Drive (4WD) gearbox - Assemble (23.304).

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Carefully clean the contact surfaces. 2. Apply approximately 2 mm of anaerobic sealant to the contact surfaces between the transmission box and the transfer box.

CUIL13TR00606AA

LAIL11TL0459A0A

LAIL11TL0458A0A

3. Use a service jack to mount the transfer box on the transmission box and tighten the fastening bolts (2) to a torque of 98.0 NÂˇm (72.3 lb ft). 4. Retighten the oil inlet pipe located under the transmission box near the transfer box. 5. Replace the front wheel drive sensor and secure it with the two fastening bolts. 6. Replace the parking brake manual stretcher on the block connecting rod.

7. Place the helical spring (1) on the lever. 8. Re-install the banjo bolt for the control valve. 9. Replace the control valve pipe in the transfer box. 10. Install the fuel tank. Consult the procedures in Fuel tank - Install (10.216).

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

11. Re-install the Cardan sleeves on the transfer box. Secure the sleeves with a lock ring (2). 12. Replace the cap. 13. Fill the transmission housing with new and recommended oil up to the correct level. See the fluid specifications and the capacity of the system in Capacities () . 14. Connect the negative battery cable.

LAIL11TL0474A0A

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Four-Wheel Drive (4WD) system - Four-Wheel Drive (4WD) gearbox

Four-Wheel Drive (4WD) gearbox - Troubleshooting Problem Possible Cause The Auxiliary Front Wheel The engage/disengage switch for the FWD Drive (FWD) does not does not work. engage. Faulty solenoid control relay. The FWD control solenoid is stuck in the open position. The connecting spring of the transfer box is deformed. The Auxiliary Front Wheel Transmission oil level is insufficient. Drive (FWD) remains engaged. Plugged oil filter. Hydraulic pump faulty. The engage/disengage switch for the FWD is defective. Failure in the power supply for the solenoid: disconnected or damaged connections, or defective contacts. The FWD control solenoid is stuck in engaged position. Oil leak in the seals causing a pressure drop: in the hub, in the piston seal or in the transmission, or in the rings that seal the transfer box shaft.

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Correction Replace the switch.

Check and if necessary replace the relay. Check and if necessary replace the solenoid. Service the unit. Top up the oil. Consult the procedures in Transmission housing - Filling (21.114). Replace the filter. Service or replace the pump. Replace the switch. Re-establish the electrical connections and replace faulty parts. Service or replace the solenoid. Replace the faulty seals.

Index Four-Wheel Drive (4WD) system - 23 Four-Wheel Drive (4WD) gearbox - 304 Four-Wheel Drive (4WD) gearbox - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Four-Wheel Drive (4WD) gearbox - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

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Contents Four-Wheel Drive (4WD) system - 23 Drive shaft - 314

SERVICE Drive shaft Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Remove 1. Remove the front, center, and rear fixing bolts from the guard for the Cardan drive of the front axle. Remove the guard.

LAIL11TL1120A0A

LAIL11TL0586A0A

LAIL11TL0587A0A

LAIL11TL0588A0A

2. Remove the lock ring (2). Remove the sleeve (1) from the front shaft pinion.

3. Disassemble the lock ring (2) and remove the sleeve (1) from the transfer box.

4. Loosen the bolts securing the prop shaft central support (1) and remove the entire prop shaft with the support.

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install (23.314) .

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Four-Wheel Drive (4WD) system - Drive shaft

Drive shaft - Install Prior operation: Drive shaft - Remove (23.314) 1. Install the Cardan shaft and the central support for the shaft.

LAIL11TL0588A0A

LAIL11TL0587A0A

LAIL11TL1120A0A

2. Install the sleeve (1) and the lock ring (2) for the transfer box. 3. Install the sleeve and the lock ring for the front shaft pinion.

4. Install the guard for the Cardan shaft and tighten the front, center and rear bolts.

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Index Four-Wheel Drive (4WD) system - 23 Drive shaft - 314 Drive shaft - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Drive shaft - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Front axle system TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Front axle system - 25

[25.100] Powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 [25.102] Front bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.2 [25.108] Final drive hub, steering knuckles, and shafts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.3 [25.400] Non-powered front axle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.4

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

Reference

PAGE

Front bevel gear set and differential - Install

25.2 / 18

Differential - Install Differential - Install

25.2 / 23 25.2 / 23

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Contents Front axle system - 25 Powered front axle - 100

TECHNICAL DATA Powered front axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Powered front axle Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Powered front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Alignment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Axle housing Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

DIAGNOSTIC Powered front axle Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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Front axle system - Powered front axle

Powered front axle - General specification Type Shafts and Turning Housings Diameter of external shafts (9)* in relation to the bushings (8)* Internal diameter of the installed bushing (8)* Clearance between the shafts and bushes Interference between bushes and the respective holes Pin adjustment shim thickness (7)* Axle articulation Clearance of end between axle housing and bearings Maximum admissible clearance Articulated axle front pin diameter Internal diameter of front bushing installed Pin-to-bushing clearance Rear bush external diameter installed in bevel pinion support External diameter of rear bush installed in articulated axle support Clearance between the two bushes and pins Shim thickness of front and rear front axle backing (1)

TL60E TL75E TL85E TL95E Steering, load support structure, central articulation 41.975 - 42.000 mm 45.100 - 45.175 mm(1) 0.100 - 0.200 mm 0.064 - 0.129 mm 0.10 mm - 0.15 mm - 0.20 mm - 0.25 mm - 0.30 mm 0.3 - 1.1 mm 2 mm 52.652 - 52.671 mm 52.720 - 52.790 mm(1) 0.049 - 0.138 mm 99.020 - 99.050 mm 99.146 - 99.221 mm(1) 0.096 - 0.201 mm 4.90 - 5.00 mm

Measurement to be achieved without enlargement

(*) See the references in Wheel hub - Sectional view (25.108).

Powered front axle - Special tools 380000257 380000268

Bevel Gear Pinion Splined Retainer Deep Socket Bevel Pinion Ring Nut Wrench

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Front axle system - Powered front axle

Powered front axle - Torque

LAIL11TL1028G0A

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Front axle system - Powered front axle

Reference (A) (B) -

Description Crown fixing bolt Pinion fastening nut Axle housing steering assembly fixing nut

(C)

Fastening nut for the steering support pin

(D) (E) (F) (G) (H) (J) (K) (L) (M)

Fastening nut for wheel hub bearing Fastening bolt for hub cover Fastening nut for upper engine Bearing fastening bolt Differential cover bolt Wheel rim fixing bolt nut Fastening bolt for differential in front axle housing Nut for adjusting differential bearing pre-load Fastening bolt for adjustment lock

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Torque 113 N·m (83 lb ft) 294 N·m (217 lb ft) 113 N·m (83 lb ft) TL60E: 64 N·m (47 lb ft) Other models: 113.0 N·m (83.3 lb ft) 392 N·m (289 lb ft) 64 N·m (47 lb ft) 314 N·m (232 lb ft) 314 N·m (232 lb ft) 113 N·m (83 lb ft) 245 N·m (181 lb ft) 113 N·m (83 lb ft) 35 - 59 N·m (26 - 44 lb ft) 113 N·m (83 lb ft)

Front axle system - Powered front axle

Powered front axle - Dynamic description The tractors are equipped with a central Auxiliary Front Wheel Drive (AFWD) and a coaxial drive shaft in the longitudinal direction of the tractor. The drive shaft has no universal joints. The differential has two planetary gears and movement is transmitted to the lateral epicyclic final units (installed in the wheel hubs) through universal joints that do not require any maintenance. The entire gear, shaft and bush assembly is submerged in lubricant oil SAE 10W30, which requires the use of special additives given that the differential used in these tractors does not have a skid control system (it is not self-locking). The final epicyclical reduction (hubs) is also lubricated using the same type of lubricant oil. However, if retainers are available, an independent reservoir becomes necessary for each unit, thus allowing a separate maintenance period (oil change interval) to that of the shaft. This ensures improved durability of the final drive unit.

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Front axle system - Powered front axle

Powered front axle - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

NOTE: The front axle assembly can be removed from the tractor with or without prior disassembly of the transmission shaft. The description below refers to the removal of the front axle with the transmission shaft installed in the tractor. To disassemble the transmission shaft see the procedures described in Drive shaft - Remove (23.314) Depending on the work to be done on the axle, it could be a help to loosen certain nuts before removing the axle from the tractor. For Example: • Wheel hub bearing nuts on the right and left sides. • Pinion safety nut. • Wheel shaft end nuts. Proceed as follows: 1. Disconnect the negative (−) battery cable (1) from the battery. 2. Drain the front axle oil. Consult the procedures in Axle housing - Drain fluid (25.100). 3. Drain the oil from the front axle hub. Consult the procedures in Wheel hub - Drain fluid (25.108).

CUIL13TRO0194AA

LAIL11TL0485A0A

4. Remove the bolts (1) and remove the front mudguard supports (2). 5. Remove the front ballasts. Consult the procedures in Front ballast - Remove (39.140).

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Front axle system - Powered front axle

6. Loosen the (1) from the steering cylinder rigid pipes (2) and loosen the two flexible pipes (3).

LAIL11TL0487A0A

LAIL11TL0484A0A

LAIL11TL0488A0A

LAIL11TL0492A0A

7. Remove the bolts (1) and disassemble the transmission shaft protection (2).

8. Expand and slide the lock ring (1) and sleeve (2) over the front wheel drive shaft. 9. Remove the front wheels. Consult the procedures in Front wheels - Remove (44.511) .

10. Loosen the fixing bolts (1) of the rear axle support.

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Front axle system - Powered front axle

11. Loosen the fixing bolts (1) of the front wheel drive support.

LAIL11TL0493A0A

CUIL13TR00801AA

LAIL11TL0044A0A

12. Using a lifting hook and two nylon cables (1) (one for each side), separate the front axle from the tractor.

13. Remove the bushings and other front axle supporting components, according to the sequence in the figure to the side. 1.

Front support column

"O" segment

Spacer

Sealant

Rear support column

Next operation: Powered front axle - Disassemble (25.100) .

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Front axle system - Powered front axle

Powered front axle - Disassemble Prior operation: Powered front axle - Remove (25.100) . 1. Position the front axle on a review support as shown in the figure to the side.

LAIL11TL0045A0A

LAIL11TL0032A0A

LAIL11TL0033A0A

2. Remove the front axle rear support (1). 3. Disassemble the front support and remove the ferrule.

4. Loosen the two fastening bolts (1) from the wheel axle.

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Front axle system - Powered front axle

NOTE: Before removing the wheel axle, make sure that the hubs will not turn on the articulations, causing the axle to fall from the work bench. 5. Using the dismounting tool, remove the pins from their holes in the housing and remove the axle from the wheels.

LAIL11TL1089A0A

LAIL11TL0034A0A

LAIL11TL0039A0A

LAIL11TL0046A0A

6. Remove the retaining rings (2) from the articulated pins on the cylinder rod, unbolt the cylinder pin (1) fastening bolts, remove the pins and separate the two cylinders. 7. Remove the four pins, rings, spacers and the cylinders complete with tubes. 8. Remove the wheel hub. Consult the procedures in Wheel hub - Disassemble (25.108).

9. Remove the bolts (1) from the lower articulation pin. 10. Remove the bottom articulated pin and the corresponding adjusting shims.

11. Remove the four fastening bolts (1) from the mudguard support (2) and remove the support.

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Front axle system - Powered front axle

12. Remove the three fixation bolts from the top articulated pin. 13. Remove the upper articulation pin (1). 14. Remove the axle housing (2).

LAIL11TL0040A0A

LAIL11TL0047A0A

15. Remove the fixing bolt (2) from the shaft (1).

16. Remove the shaft (1) from the box. NOTE: Repeat the previous 8 steps on the other side of the shaft. 17. Remove the front axle differential. Consult the procedures in Front bevel gear set and differential - Remove (25.102).

LAIL11TL0029A0A

LAIL11TL0052A0A

18. Straighten up the lock tab on the safety nut (1) of the splined shaft.

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Front axle system - Powered front axle

19. To loosen the pinion nut, it is necessary to use a tool 380000257 that holds the pinion shaft.

LAIL11TL0053A0A

LAIL11TL0054A0A

LAIL11TL0055A0A

LAIL11TL0056A0A

20. Remove the nut using tool 380000268 (1) while using tool 380000257 to prevent the bevel pinion shaft from turning.

21. Remove the retention ball from the sleeve.

22. Remove pinion shaft (1) from the rear part of the box and remove the spacer, adjustment shims and bearing.

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Front axle system - Powered front axle

23. Remove the dust seal, oil seal (1) and the rear bearing.

LAIL11TL0057A0A

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Front axle system - Powered front axle

Powered front axle - Alignment LA ---

TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA --LA --LA ---

Checking the alignment between the wheels and steering When moved in a straight line, the wheels on machines with Auxiliary Front-Wheel Drive (AFWD) must be parallel to the longitudinal axis of the machine, and/or, as an alternative, a slight convergence of the front wheels is allowed, up to a maximum value of 6 mm measured from the extremities of the wheel rims. To check the exact convergence adjustment value for a front-wheel drive machine, proceed as follows: 1. Calibrate the front tires to recommended pressure. 2. Position the steering wheel so that the front wheels are aligned with the machine. 3. Check if the wheels are parallel with the longitudinal axis of the machine. 4. Measure the distance (1) between the internal front ends of the wheels at the height of the centre of the wheel hubs.

LAIL11TL0498A0A

5. Turning the wheels 180 Â° is necessary to eliminate the influence of any wear to the wheels on the measurement. Turn the front wheels 180 Â° and re-measure the distance between (2) the inner ends of the wheel at the height of the center of the wheel hub. 6. The measurement (2) must vary within 6 mm of the measure (1).

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Front axle system - Powered front axle

7. If it is necessary to correct the wheel alignment, disassemble the nut (2) and remove the wheel shaft stub (1) out of its housing. Loosen the nut (3) and adjust the terminal (1) inward or outward to increase or reduce the distance (2), figure 1. 8. Replace the terminal (1) in its housing and check the alignment again, as described in items 4 and 5. 9. After the alignment has been adjusted within the recommended limits, fasten nut (3) to a torque of 180 NÂˇm (132.8 lb ft) and nut (2) to 100 NÂˇm (73.8 lb ft). NOTE: The auto-lock nut (2) must be replaced every time it is removed or partially loosened.

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LAIL11TL0082A0A

Front axle system - Powered front axle

Axle housing - Drain fluid 1. Place a suitably sized container under the component. 2. Remove the plug (1) to drain the fluid. 3. Dispose of the collected fluid in an appropriate manner. Adhere to the legislation in effect in your region or country.

CUIL13TRO0223AA

Next operation: Axle housing - Filling (25.100)

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Front axle system - Powered front axle

Axle housing - Filling Prior operation: Axle housing - Drain fluid (25.100) . 1. Fill the lubricating oil through the plug nozzle (1). 2. See the specification and quantity of fluid in Capacities (). 3. Install plug (1).

CUIL13TRO0223AA

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Front axle system - Powered front axle

Powered front axle - Troubleshooting Problem Abnormal tyre wear

Possible Cause Incorrect tyre pressure.

Low tractor stability

Incorrect front wheel toe-in. Incorrect tyre pressure Incorrect gauge adjustment

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Correction Fill the tyres to the pressure recommended in the operator manual. Correct toe-in Fill the tyres correctly as indicated above If possible, adjust the tractor to work with a greater distance between the wheels

Index Front axle system - 25 Powered front axle - 100

(*)

Axle housing - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle housing - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Alignment (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered front axle - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

25.1 [25.100] / 20

specific

models

Front axle system - 25 Front bevel gear set and differential - 102

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Contents Front axle system - 25 Front bevel gear set and differential - 102

TECHNICAL DATA Differential General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Front bevel gear set and differential Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Differential Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

SERVICE Front bevel gear set and differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Depth adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Differential Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

(*) See content for specific models 47835583 21/10/2015

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

Reference

PAGE

Front bevel gear set and differential - Install

25.2 / 18

Differential - Install Differential - Install

25.2 / 23 25.2 / 23

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Front axle system - Front bevel gear set and differential

Differential - General specification Pinion-crown gear ratio Clearance Between the pair of bevel gears: Thickness of the adjustment shim (5)* for adjusting the position of the pinion Thickness of the adjustment shim (4)* for the pinion bearing Clearance between planetary and satellite (gear) teeth Planetary shim thickness Satellite shim thickness Transverse pin diameter for the satellites Diameter of satellite transversal holes

TL60E 9/29 = 1:3,222

TL75E

TL85E 9/39 = 1:4,333 0.15 - 0.20 mm

TL95E

2.5 - 3.7 mm at 0.1 mm intervals 2.5 - 4.8 mm at 0.05 mm intervals 0.15 mm 1.470 - 1.530 mm 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm - 1.8 mm 21.939 23.939 - 23.960 mm 21.960 mm 22.040 24.040 - 24.061 mm 22.061 mm

Clearance between transversal pins and holes Diameter of lateral planetary hubs Hub hole diameter of lateral planetaries in the differential box Clearance between satellites and holes

0.080 - 0.122 mm 43.961 - 44.000 mm 44.080 - 44.119 mm 0.080 - 0.158 mm

(*) See the references in Differential - Sectional view (25.102).

Differential - Special tools 380000249 380000248 380000600 380000257 380000268 380000548 380000253

Universal Pinion Installation Tool Kit Bevel Pinion Bearings Adjusting Gauge Bevel Pinion Shimming Adjusting Gauge Bevel Gear Pinion Splined Retainer Deep Socket Bevel Pinion Ring Nut Wrench Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25) Tool to adjust the clearance between the teeth and the differential bearing preload

Tools to be made in the workshop Tool to be manufactured for the front axle pinion bearings without brake. Dimensions in mm. Made using UNI C40

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Front axle system - Front bevel gear set and differential

CUIL13TR00716AA

The tool to be manufactured for adjusting the bevel pinion is used together with tool 380000248. Made using UNI C40

LAIL11TL0483A0A

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Sectional view Front wheel drive cross-section

LAIL11TL0978F0A

Reference (1) (2) (3)

Component Tractor axle front support bush Front backing washer Front articulated pin

Reference (4) (5) (6)

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Component Rear backing washer Rear axle support bushing Rear axle support bushing (seat)

Front axle system - Front bevel gear set and differential

Differential - Exploded view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Transmission pinion components

LAIL11TL0954F0A

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Shim (pinion depth) Bearing Bearing cup Cage Nut Anti-dust cover Sealant Ball

Reference (9) (10) (11) (12) (13) (14) (15)

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Component Sleeve Bearing Bearing cup Shim (Pinion bearing pre-load) Spacer "O" segment Pinion

Front axle system - Front bevel gear set and differential

Differential - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Cross-sectional diagram of the Differential without skid control

LAIL11TL1029G0A

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Front axle system - Front bevel gear set and differential

Reference (1) (2) (3)

Component Pinion oil seal Pinion Nut Pinion

Reference (8) (9) (10)

(4)

Pinion bearing preload shimming

(11)

(5)

Pinion depth shim Nut for adjusting differential bearing pre-load Nut safety lock for adjusting the differential bearing pre-load

(12)

Component Crown wheel Planetary gap adjustment shim Steel separator plate Nut for adjusting differential bearing pre-load Planetaries

(13)

Satellites

(6) (7)

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Remove Prior operation: Powered front axle - Remove (25.100). 1. Remove the two fixation bolts from the conic support of the transmission-differential to the shaft box. 2. Bolt the two studs 380000548 (1). 3. Remove the remaining bolts and separate the differential support from the axle housing. 4. Connect a winch (2) to the support and remove the differential support (3) from the axle housing.

LAIL11TL0041A0A

LAIL11TL0042A0A

LAIL11TL0048A0A

LAIL11TL0049A0A

5. Install two fasteners (1) with appropriate capacity in the workbench vise. 6. Fasten the differential support to the tool and remove the lifting cable. 7. Remove the bolt (2) and remove the protection from the retaining nut (3). 8. Repeat the operation 7 for the other side of the differential.

9. Remove the differential adjustment nut using tool (1) 380000252.

10. Remove the two fastening bolts from the crown covers of the transmission box (1).

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Front axle system - Front bevel gear set and differential

11. Remove the bearing (1) and cover (2) of the differential bearing. 12. Repeat the operation on the opposite side.

LAIL11TL0050A0A

LAIL11TL0051A0A

13. Remove the differential from the support.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Depth adjust Pinion depth adjustment The aim of this procedure is to determine the adjustment shim (1) thickness of the bevel pinion position.

LAIL11TL0065A0A

LAIL11TL0060A0A

LAIL11TL0061A0A

LAIL11TL0062A0A

1. Install the pinion bearings in the differential support housing and fasten them in position with the tool 380000248. 1.

Pinion measuring cone - tool number 380000249.

Pinion bearing clamp. 380000248 as shown.

Pinion bearings.

Micrometer (Tool part number 380000249).

Use tool number

2. Install the roller bearings and tighten the fastening nuts to a torque of 113 NÂˇm. 3. Install tool 380000249 (1) in the differential housing.

4. Adjust the cones of tool 380000249 so that the tip of the micrometer touches the internal track of the pinion bearing and measure the size (H3).

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Front axle system - Front bevel gear set and differential

Distance between the centre of the differential and the support base of the bearing in the pinion 1. Determine the corrected distance (H5) between the centre of the differential and the support base of the bearing in the pinion: H5 = H4 + C, where: • (H4) : 115 mm. Nominal distance between the center of the differential and the support base of the bearing in the pinion.

LAIL11TL0062A0A

LAIL11TL0497A0A

2. • (C): Correction value entered in pinion preceded by + or - sign (if different from 0). This value should be added to or subtracted from the nominal distance (H4) according to the sign, as indicated to the side. 3. For the example given, the measurement (H5) will be 115 mm + 0,2 mm = 115,2 mm

Thickness of adjustment shim 1. The shim thickness will be determined by the formula S = H3 - H5, where: • S: shim thickness • H3: distance measured with the micrometer • H5: corrected nominal distance between the centre of the differential and the support base of the bearing in the pinion. 2. For the example already used, the shim thickness will be: • S = 118 mm - 115.2 mm = 2.8 mm

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Adjust Pinion shim adjustment 1. Install the roller bearings (without the bearing cover) and fasten with a torque of 113 N·m (83.3 lb ft). 2. Measure the internal dimension of the bearing diameter and call this dimension (A). 3. Install the pinion bearings in the differential support housing and fasten them in position with tool 380000600. NOTE: Fasten the clamp so that the bearing cones can be turned by hand.

LAIL11TL0063A0A

LAIL11TL0064A0A

LAIL11TL0065A0A

4. Place the template bar, tool part number 380000600, through the bearing diameter and measure dimension 'B'. 1.

Depth Micrometer

Template bar- Tool part 380000600.

Pinion shaft bearings

Tool 380000600.

Differential; support box

5. Calculate dimension H4 using the formula H4 = B-25*+(A/2) NOTE: *The template bar 380000600 has a diameter of 25 mm 6. Determine the thickness of shims “S2” which will be installed behind the pinion gear as follows: S2 = H4 - H3 Where: H4 = Dimension calculated in step 5 above H3 = 115 mm + correction factor (C) 115 mm is the manufacturer's nominal dimension of the rear face of the pinion gear to the conical tip of the pinion. (Supplied by the manufacturer). C = Manufacturer's correction factor, engraved on the pinion face. Example A = 95 mm B = 95.77 mm H4 = B-25*+(A/2) H4 = 95.77–25*+(95/2) H4 = 118.27 C = 0.1 mm H3 = 115+0.1=115.1 Shim thickness S2 = 118.27–115.1= 3.17 mm

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Installation of the shim and pinion bearing 7. Install the shim selected in the adjustment procedure of the pinion shim between the pinion head and bearing. NOTE: Make sure that the chamber on the shim is turned facing the pinion head.

LAIL11TL0066A0A

LAIL11TL0067A0A

8. Install the bearing onto the pinion. NOTE: The use of an induction heater will help install the bearings without the use of a press.

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Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Preload Adjusting the preload of the pinion shaft bearings CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Proceed as follows: 1. Fix the tool 380000248 (1) in the vice, install the internal races of the bearings (2) and (4) the spacer (3) and fasten the tool nut until the end of run.

LAIL11TS0071A0A

LAIL11TS0072A0A

LAIL11TS0073A0A

2. Use a micrometer to measure the distance "H1" between the top surface and the pin of tool 293391 380000248 (1). 3. Disassemble the above parts. Lubricate the bearings with transmission oil. Then reinstall the parts, excluding the bearing spacer (3), Figure 1, of the differential shaft housing, complete with the external races of the bearings, held in place with the aid of the review support.

4. Tighten the nut of tool 380000248 (1) to the end, while turning the tool to ensure that the bearings are correctly seated. 5. Use a micrometer to measure distance "H2" considering the tool in this condition.

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6. The thickness required for the adjustment shim is determined by: (1) S = (H2 - H1) + 0.05 mm Example: H2 = 10.5 mm H1 = 8.3 mm S = ( 10.5 mm - 8.3 mm) + 0.05 mm S = ( 2.2 mm) + 0.05 mm S = 2.25 mm 7. Remove tools 380000248 and 380000249 from the bevel pinion housing. 8. Install the complete bevel pinion with internal bearing race, spacer, and adjustment shim with the previously determined thicknesses. Next operation: Front bevel gear set and differential - Install (25.102).

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CUIL13TR00717AA

Front axle system - Front bevel gear set and differential

Front bevel gear set and differential - Install Prior operation: Front bevel gear set and differential - Preload (25.102). 1. Fit the O-ring sealing (1) onto the pinion shaft. 2. Next, insert the retainer race and afterwards the ball, after having carefully lubricated the external surface.

LAIL11TL0071A0A

LAIL11TL0072A0A

LAIL11TL0073A0A

3. Install the pinion lock key 380000257. 4. Install key 380000268 in the pinion nut. 5. Use a key to lock the pinion. Use a torque meter positioned as shown in Figure 3 to tighten the nut to a torque of 294 N·m ( 217 lb ft). Simultaneously turn the pinion to ensure that the bearings are correctly seated.

6. Use a torque wrench and pinion lock 380000257 to check the pinion turning torque. If the turning torque is lower than the recommended value, install a thinner adjustment shim; if the torque value is higher, install a thicker adjustment shim in order to adjust it. NOTE: The pinion turning force measured with a balance must be 2,17 kgf, for both CNH class I HD and CNH class II axles

Adjustment of the preload of the pinion shaft bearings The values described are obtained with a low load torque meter (1), installed on the pinion shaft, with the bearings previously lubricated with transmission oil NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL. Turning torque Pinion 0.5 N·m

Pinion + differential 1.0 - 1.3 N·m

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Front axle system - Front bevel gear set and differential

If no torque meter is available, use a dynamometer and check the values in the table below. The turning force should be applied to a string wound around the pinion, in the grooved area. Turning force Pinion 31.7 N (7.1 lb)

Pinion + differential 63 - 82 N (14 - 18 lb)

7. After obtaining the specified value, unfasten the lock nut and install the retainer and corresponding dust seal ring. Fasten the nut to a torque of 294 NÂˇm (217 lb ft) and simultaneously turn the pinion to ensure that the bearings are correctly seated. 8. Finally, carefully lock the nut (1) and install the lock ring.

LAIL11TL0052A0A

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Front axle system - Front bevel gear set and differential

Differential - Gear tooth contact TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

When the differential assembly needs to be serviced, it will be necessary to adjust the gap between the teeth of the planetary gears and satellite gears. Proceed as follows: 1. Clean the differential components very well and carefully, and remove all the vestiges of oil that may prevent the correct measurement of clearance. 2. Install the planetary gears without the friction shims (self-locking system).

LAIL11TS0058A0A

LAIL11TS0059A0A

3. Fit in the two satellite gears complete with backing shims and fix the pin with the fixation bolt, turning it to keep the pin in place. 4. Place a calibrator gauge into the differential housing. 5. Move the planetary gear on the left-hand side in order to establish perfect contact with the satellite and then push against the differential housing and take the gap reading on the calibrator gauge “Gs”. 6. Repeat the above operation to measure the gap on the right-hand side in the other planetary gear “Gd”.

The shim to be installed in the differential housing is therefore determined by. Ss = Gs - 0.25 mm for the planetary gear on the LH side. Sd = Gd - 0.25 mm for the planetary gear on the RH side. 7. Install the shims as closely as possible to the calculated values and using the calibration gauge, follow the procedures described above, checking that the gap of the planetaries on the right and left sides is approximately 0.25 mm.

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Front axle system - Front bevel gear set and differential

Differential - Install Differential bearing adjustments and checking clearance between the pinion and crown. Proceed as follows: 1. Install the differential mounted in the housing.

LAIL11TS0050A0A

LAIL11TS0048A0A

LAIL11TL0074A0A

LAIL11TL0075A0A

2. Install the roller bearing covers in the housing case, adjust the differential cover support, fasten the bolts with torques corresponding to 59 N·m (44 lb ft) and then loosen and fasten again with a torque of 20 N·m (15 lb ft).

3. With the bearings perfectly lubricated, turn the differential and at the same time fasten the adjustment nut using wrench 380000252 ( (1) to a torque of 39 - 59 N·m (29 - 44 lb ft) to maintain the axial gap between the components.

4. Measure the gap between the pinion and crown using a 1/100 meter perpendicular to the external ridges of a crown tooth (1). 5. Repeat the measurement in different positions and compare the mean of the three values (Gm) with the recommended normal clearance: • TL60E: 0.18 - 0.23 mm (mean value of 0.20 mm) • Other models: 0.18 mm)

0.15 - 0.20 mm(mean value of

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Front axle system - Front bevel gear set and differential

6. When the measured clearance is not within the recommended tolerance thresholds, adjust the nut by tightening one of the nuts inside and the outside to the same amount. This will fix the axial preload and thereby obtain the recommended clearance.

LAIL11TL0074A0A

LAIL11TL0073A0A

LAIL11TL0074A0A

LAIL11TS0048A0A

7. After adjusting the gap between the pinion and crown teeth, check the differential turning resistance, measured at the end of the pinion, with pinion lock key 380000257 (2) and with torque meter (1) . 8. The pinion and differential turning torque is 1.0 1.3 NÂˇm. 9. Should no torque meter be available, use a dynamometer. The turning force should be applied to a string wound around the pinion, in the grooved area. 10. Pinion and differential turning force: 63 - 82 N (14.2 18.4 lb) 11. If the recommended value is not obtained, adjust the differential adjustment nuts by fastening the nuts equally to obtain the higher turning force. The maximum fastening torque of the adjustment nuts is 6 kgm. NOTE: Fastening must be applied equally on the right and left hand nuts, so as not to alter the clearance between the pinion and crown teeth.

12. Torque the bearing bolts to 113 NÂˇm (83 lb ft).

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Front axle system - Front bevel gear set and differential

13. Install the safety lock (3), fastening the adjusting nut inwards or outwards, up to the closest tooth. 14. Install the shaft housing assembly, after having carefully cleaned it and removed the oil from all of the contact surfaces and applied a coat of LOCTITE® 515™ of approximately 2 mm in thickness along the line shown in the figure below.

LAIL11TL0042A0A

Diagram for application LOCTITE® 515™ for installing the differential and complete epicyclic unit.

LAIL11TL0937B0A

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Index Front axle system - 25 Front bevel gear set and differential - 102

(*)

Differential - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Gear tooth contact (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Depth adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front bevel gear set and differential - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

25.2 [25.102] / 24

specific

models

Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

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Contents Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

TECHNICAL DATA Final drive hub, steering knuckles, and shafts Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Wheel hub Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Steering knuckle and king pin Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Wheel hub Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 47835583 21/10/2015

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Front axle system - Final drive hub, steering knuckles, and shafts

Final drive hub, steering knuckles, and shafts - Special tools 380000269 380000234 380000265 380001143 380000235 380000548 380000284

Wheel Hub Bearing Ring Socket Swivel Pin Bearing Outer Race Puller Swivel housing pin pivot puller Front Axle Shaft to Swivel Housing Mounting Guide (Class 3) Swivel Housing Torque Check Adapter Use alignment pins (M12 x 1.25) for the front axle planetary reduction hub. Wheel Hub Seal Installer

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Sectional view

LAIL11TL1098G0A

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

Component Driven gear shims of the epicyclic unit (hub) Oil seals (casette) Hub shaft oil seal Shaft fixing bolt

Reference

Component

(5)

Axel

(6) (7) (8) (9)

Shaft oil seal Articulation pin adjustment shims Axle bushing Shaft stub

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Replace TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Powered front axle - Remove (25.100) . If pins are difficult to remove, proceed as follows: 1. Remove the grease fitting and the fixing screws of the pins. 2. Fit the bolts (1) of tool 380000265. 3. Fit the plate (2) of the tool and attach it to the three bolts with nuts (5). 4. Fit the central lock bolt (4), fastening it completely into the hole in the pin's grease nipple (6). 5. Fit the nut (3) and tighten it to remove the pin.

LAIL11TL0938B0A

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Front axle system - Final drive hub, steering knuckles, and shafts

6. Using the extraction tool 380000234 (1) remove the spherical bushing. 7. Install the spherical bushings using a suitable mandrel.

LAIL11TL0077A0A

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Front axle system - Final drive hub, steering knuckles, and shafts

Steering knuckle and king pin - Adjust TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Powered front axle - Remove (25.100) .

Adjusting the steering casing DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Apply grease on the outer track of the bushing and fit the upper pin without the adjustment shims using the tool 380000235 (2) 2. Tighten the fasting bolts to a torque of 113 NÂ·m (83.3 lb ft). NOTE: To make it easier to install the casing, we recommend that guide 380001143 (1) be installed.

LAIL11TL0078A0A

LAIL11TL0079A0A

3. Fit the lower pin without adjustment shims and lubricate the three mounting bolts with engine oil. 4. Gradually tighten the lower screws in sequence, turning the casing to allow excess grease to drain out.

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Front axle system - Final drive hub, steering knuckles, and shafts

5. Use a torque wrench and tool 380000235 (1) to check that the torque needed to rotate the casing is 15 25 N·m (11.1 - 18.4 lb ft). Do not take the initial peak torque into consideration. 6. If the value is different, make an adjustment using the screws on the pin's lower flange. 7. Measure the distance (H) between the lower flange of the pin and the casing for the three screws.

LAIL11TL0080A0A

LAIL11TL0081A0A

LAIL11TL0079A0A

8. Calculate the average of the three measured values. The total thickness of the "S3" adjustment shim to be inserted under the flange of the lower pin must be calculated as follows: S3 = H - 0.20 mm. If necessary, round the values to the nearest 0.05 mm .

9. Partially loosen the screws on the flange of the lower pin and insert the shims. 10. Tighten the screws to a torque of 113 N·m (83.3 lb ft). 11. After rotating the casing a number of times to align the components, check that the torque needed to rotate the casing is 118 - 147 N·m (87 - 108 lb ft), ignoring the initial peak torque. 12. If the value measured for the torque is higher than recommended, increase the thickness of the shims, and if the value measured is less than recommended, reduce the thickness of the shims. 13. Install the grease nipples in the flanges of the top and bottom pins and lubricate the set.

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Drain fluid 1. Park the machine on a level and hard surface. 2. Place a suitably sized container under the component. 3. Place the plug in the lowest position, as per the adjacent figure. 4. Remove the plug (1) to drain the fluid.

CUIL13TR00457AA

Next operation: Wheel hub - Filling (25.108) .

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Filling Prior operation: Wheel hub - Drain fluid (25.108) . 1. Place the plug (1) in the intermediate position, as shown in the figure to the side. 2. Fill the lubricant oil level up to the lower lip of the plug nozzle. 3. See the specification and quantity of fluid in Capacities (). 4. Install plug (1).

CUIL13TR00456AA

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Front axle system - Final drive hub, steering knuckles, and shafts

Wheel hub - Disassemble Prior operation: Powered front axle - Disassemble (25.100) . 1. Remove the fastening bolts from the end of the cover (1) of the wheel hub. 2. Install the guide pins 380000548 (2). 3. Install a sliding hammer in the oil drain plug and remove the cover (1) from the wheel hub.

LAIL11TL0030A0A

LAIL11TL0035A0A

LAIL11TL0036A0A

LAIL11TL0037A0A

4. Remove the external retention ring (1) which holds the transmission gears (2) and remove the gears.

NOTE: If necessary, it is possible to remove the hub and the shaft housing stud together, without the need for removing the safety stud from the wheel hub bearing.

6. Remove the safety nut from the wheel hub bearing using special tool 380000269 (1).

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Front axle system - Final drive hub, steering knuckles, and shafts

7. Remove the wheel hub (1) using the ring gear (2). NOTE: Repeat the steps on the other side of the shaft.

LAIL11TL0038A0A

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Index Front axle system - 25 Final drive hub, steering knuckles, and shafts - 108

(*)

Final drive hub, steering knuckles, and shafts - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Adjust (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering knuckle and king pin - Replace (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Drain fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wheel hub - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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Front axle system - 25 Non-powered front axle - 400

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Contents Front axle system - 25 Non-powered front axle - 400

TECHNICAL DATA Non-powered front axle General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Non-powered front axle Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Non-powered front axle Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Axle wheel hub Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

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Front axle system - Non-powered front axle

Non-powered front axle - General specification Type Wheel angle Toe-in Stub axle articulation Shaft diameter at stub axle (7)** at bushings Inside diameter of installed bushes (6)** Play between the stub axle shaft and corresponding bushings Axle articulation Linkage pin diameter (1)** Inside diameter of installed bushes (6)** Play between the pin and corresponding bushings

TL75E Inverted U, telescopic, and center-swinging 2 Â°, corresponding to 15 mm for 16 in wheels 0 - 5 mm 37.961 - 38.000 mm 38.050 - 38.140 mm (*) 0.050 - 0.179 mm 37.961 - 38.000 mm 38.050 - 38.140 mm (*) 0.050 - 0.179 mm

(*) Value to be attained without passing the enlarger (**) See the references in Non-powered front axle - Sectional view (25.400).

Non-powered front axle - Special tools Special tools NOTICE: The tools that appear below with the symbol "X" are ESSENTIAL for the operations described in this section. However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction drawings given in this Manual. List of specific tools needed to perform the different operations described in this Section. X 380000541 380000549

Axle Pivot Pin Adaptor (M12 x 1.25) Sliding hammer

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Front axle system - Non-powered front axle

Non-powered front axle - Torque

LAIL11TL1046G0A

(C3) (C5) (C6)

Bearing adjusting nut Stub axle control lever bolt fixing nut Nut fixing the cylinder to the axle

Reference (C1) (C4) (C2)

Part Front axle Shaft to engine fixing bolt Articulation pin fixing bolt Fixing nut for the axle end bolt Stub bolt lever fixing nut Fixing nut for the cross bar terminals Wheel to hub fixing bolt

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Turnbuckle

Torque

M18 x 1.5 M10 X 1.25 M16 X 1.5 M16 X 1.5 M14 x 1.5 M18 x 1.5

353 N·m (260 lb ft) 49 N·m (36 lb ft) 211 N·m (156 lb ft) 294 N·m (217 lb ft) 118 N·m (87 lb ft) 314 N·m (232 lb ft)

Front axle system - Non-powered front axle

Non-powered front axle - Sectional view

LAIL11TL1045G0A

Reference (1) (2) (3) (4) (5) (6)

Component Pivot pin Articulation pin bushes Cross bar Stub axle control lever Pin support Bushings

Reference (10) (11) (12) (13) (14) (15)

(7)

Stub axle

(16)

(8) (9)

Support ring

(17) (18)

Cover

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Component Bronze thrust ring Sealant Wheel hub Steel support ring Ring (10) and cover (9) stud Hub conical bearings Cover for bearing lubrication and adjustment Cylinder support pin (18) Steering cylinder installation position

Front axle system - Non-powered front axle

Non-powered front axle - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

To remove the complete axle from the tractor, proceed as follows: 1. Disconnect the negative battery cable from the battery. 2. Place a shim on the rear wheels and use a nylon cable to lift the front of the tractor.

LAIL11TL0920A0A

LAIL11TL0921A0A

LAIL11TL0922A0A

3. Place a trestle (1) under the engine sump and insert a wooden block between the engine sump and the trestle.

4. Remove the front wheel fixing bolts (1).

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Front axle system - Non-powered front axle

5. Disconnect the hoses (1) on the steering hydraulic cylinder (2). NOTE: Mark the hoses with the respective connections to facilitate installation.

LAIL11TL0923A0A

LAIL11TL0924A0A

LAIL11TL0925A0A

LAIL11TL0926A0A

6. Remove the articulation pin fixing bolt (1).

7. Fasten the axle with a nylon cable (1).

8. Remove the axle articulation pin (1) using an extractor with a sliding hammer 380000549, equipped with an adapter 380000541and extension (1).

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Front axle system - Non-powered front axle

9. Disassemble the complete axle (1).

LAIL11TL0927A0A

Next operation: Non-powered front axle - Install (25.400) .

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Front axle system - Non-powered front axle

Non-powered front axle - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Non-powered front axle - Remove (25.400) . 1. To re-install the complete shaft, follow the disassembly procedure in reverse order. See the torque for bolts and nuts in Non-powered front axle - Torque (25.400). 2. Install the axle articulation pin (1) using a bronze punch. 3. Install the fixing bolt on the axle articulation pin.

LAIL11TL0928A0A

LAIL11TL0929A0A

4. Reinstall the hoses (1) on the steering hydraulic cylinder.

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Front axle system - Non-powered front axle

Non-powered front axle - Toe in adjust Check the front wheel alignment, bearing in mind that in order to drive in a straight line, the wheels must be at an angle of 2 Â° in relation to the ground, which corresponds to a difference of approximately 15 mm for 16 in wheels between the top and bottom ends of the rim ridges.

LAIL11TL0917A0A

LAIL11TL0918A0A

When driving in a straight line, the wheels must also be parallel to the longitudinal axis of the tractor, or with at most a 5 mm toe-in at the front, measured between the wheels. To check the precise toe-in, proceed as follows: 1. Inflate front tyres to a pressure of 2.5 bar (36 psi). 2. Align the wheels by moving the tractor forward. 3. Check if the wheels are parallel with the longitudinal axis of the tractor. 4. On the horizontal plane between the wheel centers, measure the distance (B) between the front inner edge of the wheel. Make marks on the rims. 5. Move the tractor forward along a straight line until the wheels move half a turn. 6. Measure the back part at the points of the markings made in point 4. The measurement must be equal to or up to 5 mm greater than the measurement of item 4. 7. To correct the toe-in, if required, adjust on the steering bar terminal.

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Front axle system - Non-powered front axle

Axle wheel hub - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

The wheel hub may be removed without removing the axle from the tractor by proceeding as follows on each wheel: 1. Disconnect the negative battery cable from the battery. 2. Place a shim on the rear wheels and use a nylon cable to lift the front of the tractor.

LAIL11TL0920A0A

LAIL11TL0921A0A

LAIL11TL0922A0A

3. Place a trestle (1) under the engine sump and insert a wooden block between the engine sump and the trestle.

4. Loosen the front wheel fixing bolts (1).

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Front axle system - Non-powered front axle

5. Disassemble the cover (1) to lubricate the wheel hub bearings.

LAIL11TL0903A0A

LAIL11TL0904A0A

LAIL11TL0905A0A

LAIL11TL0906A0A

6. Unlock the wheel hub bearing adjustment nut (1).

7. Use a special wrench to loosen the wheel hub bearing adjustment nut.

8. Disassemble the entire wheel hub (2) and remove the bearings (1) and (3).

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Front axle system - Non-powered front axle

9. Change the worn bearings and seals using adequate extractors and punches.

LAIL11TL0907A0A

LAIL11TL0906A0A

10. Lubricate the wheel hub with GR75MD grease.

Next operation: Axle wheel hub - Install (25.400) .

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Front axle system - Non-powered front axle

Axle wheel hub - Install WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Axle wheel hub - Remove (25.400) . 1. Install the entire wheel hub (2) with the bearings (1) and (3).

LAIL11TL0906A0A

LAIL11TL0908A0A

LAIL11TL0904A0A

2. Use a torque meter to tighten the nut to a torque of 92.0 - 104.0 N·m (67.9 - 76.7 lb ft), while turning the wheel hub (1) to secure the bearings. 3. Loosen the nut and retighten it to a torque of 27.0 40.0 N·m (19.9 - 29.5 lb ft), continuously turning the wheel hub. NOTE: The nut must be replaced with a new one whenever the wheel hub is assembled.

4. Check the turning torque, which must be a maximum of 0.8 kgm. 5. Lock the nut (1). 6. Reinstall the cover (1) to lubricate the wheel hub bearings. Apply a torque of 57.0 - 76.0 N·m (42.0 - 56.1 lb ft) .

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Index Front axle system - 25 Non-powered front axle - 400 Axle wheel hub - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Axle wheel hub - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Toe in adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Non-powered front axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Rear axle system TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015

Contents Rear axle system - 27

[27.100] Powered rear axle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.1 [27.106] Rear bevel gear set and differential . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.2 [27.120] Planetary and final drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27.3

47835583 21/10/2015

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

Reference

PAGE

Bevel pinion - Preload

27.2 / 9

Final drive housing - Service instruction

27.3 / 10

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Rear axle system - 27 Powered rear axle - 100

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Contents Rear axle system - 27 Powered rear axle - 100

TECHNICAL DATA Rear axle Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Rear axle Powered rear axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Powered rear axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Rear axle system - Powered rear axle

Powered rear axle - Torque

CUIL15TR00094FA

Toque 59.0 N路m (43.5 lb ft) 98.0 N路m (72.3 lb ft) 221.0 N路m (163.0 lb ft) 221.0 N路m (163.0 lb ft)

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

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Rear axle system - Powered rear axle

CUIL15TR00115FA

Toque 176.0 N·m (129.8 lb ft) 98.0 N·m (72.3 lb ft) 255.0 N·m (188.1 lb ft) 250.0 N·m (184.4 lb ft) 250.0 N·m (184.4 lb ft) 123.0 N·m (90.7 lb ft) 61.0 N·m (45.0 lb ft)

Reference (5) (6) (7) (8) (9) (10) (11)

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Rear axle system - Powered rear axle

Powered rear axle - Sectional view

LAIL11TL1033G0A

Reference (a) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Detail of the shaft end for machines equipped with a reverser. Gearbox drive shaft PTO drive shaft Shaft play adjustment shim Locking ring Range activation shaft Retaining half-rings Reverse drive gear Pinion position adjustment shim PTO hitch sleeve Satellites Pin

Reference

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

Component Thrust shim Ring gear Pinion Reverse driven gear Low range gear Low and high speed range hitch sleeve Gear box shaft 1st and 2nd speeds hitch synchronizer Gear support bushes rd 3 and 4th speeds synchronizer Reverse gear hitch sleeve Spacer

Rear axle system - Powered rear axle

NOTE: When assembling, apply anaerobic sealant to the surfaces (X) as shown in Mechanical transmission - Service instruction (21.114) and in Final drive housing - Service instruction (27.120).

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Rear axle system - Powered rear axle

Powered rear axle - Dynamic description The rear transmission transmits the power from the gear box to the ends of the side shafts through the pair of conical gears. The pair of conical gears is helical in type and is supported on bushings with conical bearings. The differential has two planetaries and is equipped with a differential lock controlled mechanically or hydraulically. The ends of the side shaft are of the epicyclical type and controlled by the pair of conical gears of the output semi-shaft, the same ones that control the service brakes.

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Index Rear axle system - 27 Powered rear axle - 100 Powered rear axle - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Powered rear axle - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Rear bevel gear set and differential - 106

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Contents Rear axle system - 27 Rear bevel gear set and differential - 106

FUNCTIONAL DATA Differential lock control valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Bevel pinion Depth adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Differential Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Gear tooth contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Differential lock Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Differential lock mechanical control Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

DIAGNOSTIC Differential Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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

Reference Bevel pinion - Preload

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PAGE 27.2 / 9

Rear axle system - Rear bevel gear set and differential

Differential - General specification TL60E

TL75E TL85E TL95E 9/43 = 1:4.778 0.18 - 0.23 mm Planetary Gears with the pedal Hydraulic, activated by the brake pedals Activated by the switch on the control panel 24.040 Diameter of the inner seat of the satellite gears (5)* 25.040 - 25.061 mm 24.061 mm 23.939 Diameter of the satellite pins (13)* and (20)* 24.939 - 24.960 mm 23.960 mm Gap between satellites and their pins 0.080 - 0.122 mm 0.080 - 0.122 mm Diameter of the planetary seats in the differential 44.080 51.100 - 51.146 mm casing (3)* 44.119 mm 43.961 Diameter of the planetary hub (17)* and (18)* 50.954 - 51.000 mm 44.000 mm Gap between the planetary hubs and the differential 0.080 - 0.158 mm 0.100 - 0.192 mm casing 1.85 mm - 1.90 mm - 1.95 mm - 2.00 mm - 2.05 mm 2.10 mm - 2.15 mm - 2.20 mm - 2.25 mm - 2.30 mm Shims for adjusting the position of the pinion (8)** 2.35 mm - 2.40 mm - 2.45 mm - 2.50 mm - 2.55 mm 2.60 mm - 2.65 mm - 2.70 mm Thickness of the shims for adjusting the pre-load of 0.15 mm - 0.20 mm - 0.50 mm the bearings for the differential (21)* and (22)* Clearance between planetary and satellite (gear) 0.15 - 0.18 mm teeth 1.4 mm - 1.5 mm - 1.6 mm Thickness of the planetary adjustment shims (16)* 1.4 mm - 1.5 mm - 1.6 mm - 1.7 mm 1.7 mm - 1.8 mm and (17)* 1.8 mm - 1.9 mm 2.0 mm Thickness of the satellite shims (4)* 1.470 - 1.530 mm Differential lock fork adjustment shim 0.5 mm Spring to unlock the differential (mechanical control) 220 mm – Length of the spring without load Spring to unlock the differential (mechanical control) – Length of the spring under a load of 177 - 195 N 157.5 mm (40 - 44 lb) Spring to unlock the differential (electrohydraulic 237 mm control) – Length of the spring without load Spring to unlock the differential (electrohydraulic control) – Length of the spring under a load of 304 159.5 mm 335 N (68 - 75 lb) Pinion/crown pair ratio Gap between the pinion/crown teeth Type of differential Differential lock activation Unhitching the differential lock Electric hydraulic activation of differential lock

(*) See the references in Final drive housing - Sectional view (27.120). (**) See the references in Powered rear axle - Sectional view (27.100).

Differential - Special tools 380000249 380000253

Universal Pinion Installation Tool Kit Tool for adjusting the preload of the differential bearing

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Rear axle system - Rear bevel gear set and differential

Tools to be made in the workshop Tool to be manufactured to adjust the position of the conical pinion shaft (Number 583192 inscribed on the tool â&#x20AC;&#x201C; Values in mm). Build using the material Aq 45.

LAIL11TL0984F0A

LAIL11TL0663A0A

Tool to be manufactured to move the differential lock sleeve (number 50041 inscribed on the tool â&#x20AC;&#x201C; Values in mm). Build using the material C40.

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Rear axle system - Rear bevel gear set and differential

Differential lock control valve - Dynamic description The differential lock is kept disengaged by the spring (4), which exerts a force on the fork (3), as shown in the figure to the side. Figure 1: Differential lock disengaged.

CUIL13TR00610AA

CUIL13TR00609AA

The corresponding switch on the control panel is used to activate the solenoid that drives the oil from the pump to the gallery (1). Inside the gallery, the oil acts on the piston (2) and overcomes the resistance of the spring, (4) moving the rod (5), fork (3) and the coupler and thus hitching the differential lock. When the switch is turned off to disengage the differential lock, the spring (4) exerts a force on the fork (3), the rod (5) and the piston (2), which unloads the oil through the corresponding solenoid. Figure 2: Differential lock engaged.

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Depth adjust The following procedure determines the thickness of the shim (1) for positioning the bevel pinion.

CUIL15TR00173FA

LAIL11TL0516A0A

LAIL11TL0517A0A

LAIL11TL0518A0A

1. Assemble the cover for the rear tapered bearing on the transmission box (1) and the cover for the front tapered bearing. NOTE: During this procedure, do not assemble the adjustment shim (2) located between the transmission housing and the cover for the rear bearing.

2. Position the bearing (2) on the tool 583192 (1). NOTE: Assemble the shim between the front and rear bearings. 3. Insert the bearing (3) and lock the tool (1).

4. Position the tool 380000249 (2) with the cones on the differential journals. 5. Insert the micrometer (1) with a long stem into its seat and lock using the bolt.

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Rear axle system - Rear bevel gear set and differential

6. Adjust the two cones (1) and (2) in order to move the shaft of the micrometer to the position of the bearing. 7. Adjust the cones (1) and (2) manually to lock the tool onto the supports and eliminate any end play. 8. Move the tool rod to stay in contact with the bearing and measure the value H1. By way of an example, let us consider the value for H1 = 147.90 mm (5.82 in).

LAIL11TL0519A0A

LAIL11TL0497A0A

LAIL11TL0519A0A

9. Calculate the corrected nominal distance H3 between the center of the differential and the support base of the bearing in the pinion. Use the formula H3 = H2 + C, where: • H2 = Nominal distance between the center of the differential and the support base of the bearing in the pinion. The standard value used is 145.50 mm (5.73 in). • C = The correction value inscribed on the pinion, expressed in millimeters and preceded by a plus (+) sign or a minus (-) sign. The value may also be 0. This value must be added if preceded by a (+) sign, or subtracted if preceded by a (-) sign. NOTE: If the value on the pinion is, for example, - 0.2 mm, the formula will be H3 = H2 - C. If the value on the pinion is, for example, 0, the formula will be H3 = H2. 10. If the value inscribed on the pinion is as in the figure to the side, the H3 measurement will be: • H3 = 145.50 mm (5.73 in) + 0.2 mm = 145.700 mm (5.736 in). 11. The thickness S of the adjustment shim is calculated by the formula S = H1 - H3. For the measurements used above, the adjustment shim will be: • S = H1 - H3 • S = 147.900 mm (5.823 in) - 145.700 mm (5.736 in) = 2.800 mm (0.110 in)

Next operation: Bevel pinion - Preload (27.106).

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Rear axle system - Rear bevel gear set and differential

Bevel pinion - Preload Prior operation: Bevel pinion - Depth adjust (27.106). Adjusting the pre-load of the pinion shaft conical bearings. 1. In the transmission housing, install the outer race (1) of the bearing with the shim depth (2) previously calculated.

LAIL11TL0520A0A

LAIL11TL0499A0A

LAIL11TL0521A0A

2. Install the complete pinion with the parts. 3. Tighten the adjustment nut (1) while rotating the pinion shaft in order to seat the bearings. Tighten to a torque of 1.50 - 2 NÂˇm (1.1 - 1.5 lb ft). 4. Using a dynamometer and some string, measure around the low-speed gear on the pinion. Make sure that the gearbox shaft is not displaced.

5. The specified torque corresponds to a force measured with dynamometric scales (1) of 17.6 - 23.5 N (4.0 5.3 lb). NOTE: The pinion shaft conical bearings must be lubricated with NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL oil. The values informed are in movement, therefore, the initial force (starting) is not to be considered.

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6. Having adjusted the conical bearing pre-load, fold the safety latch (1) over the adjustment nut.

LAIL11TL0522A0A

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Rear axle system - Rear bevel gear set and differential

Differential - Remove Prior operation: Mechanical transmission - Remove â&#x20AC;&#x201C; Machines with platform (21.114). 1. Disassemble the oil intake (1). Tighten one of the bolts. Remove the piston (2) for operating the electrohydraulic differential lock.

LAIL11TL0650A0A

LAIL11TL0651A0A

LAIL11TL0652A0A

2. Loosen the bolts (1), remove the retaining plate (2) and remove the adjustment shims.

3. Use a punch to remove the spring pin (2) holding the engagement fork (1) of the differential lock. 4. Remove the rod (4) and remove the helical spring (3) and the fork.

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5. Loosen the bolts and remove the lock (1) of the differential adjustment nut. NOTE: Perform the procedure on the other side of the component.

LAIL11TL0653A0A

LAIL11TL0654A0A

6. Loosen the differential journal bolts (1). NOTE: Perform the procedure on the other side of the component. 7. Remove the differential from the transmission housing.

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Rear axle system - Rear bevel gear set and differential

Differential - Gear tooth contact When the differential assembly needs to be serviced, it will be necessary to adjust the gap between the teeth of the planetary gears and satellite gears. Proceed as follows: 1. Loosen the crown wheel fixing bolts (1).

LAIL11TL0523A0A

LAIL11TL0524A0A

LAIL11TL0525A0A

LAIL11TL0526A0A

2. Loosen the crown wheel (1) from the differential housing . NOTE: The differential set can also be disassembled without removing the crown wheel.

3. Loosen the locking bolts (1) which fasten the differential bushing retaining pin.

4. Remove the dowel pin from the differential housing using a suitable tool.

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Rear axle system - Rear bevel gear set and differential

5. Remove the satellite gear pin (1) smoothly.

LAIL11TL0527A0A

LAIL11TL0528A0A

LAIL11TL0529A0A

LAIL11TL0530A0A

6. Remove the differential gears and thrust washers.

7. Remove the side gears and thrust washers. 8. Use suitable extractors to remove the bearings from both the sides.

9. Remove the differential coupling/locking sleeve from the housing.

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Rear axle system - Rear bevel gear set and differential

10. Clean the differential components very well and carefully, and remove all the vestiges of oil that may prevent the correct measurement of clearance. 11. Install the planetary gears (2) and (5) without adjustment shims (6). 12. Fit in the two (3) and (8) satellite gears complete with backing shims and fix the pin (4) with the fixation bolt, turning it to keep the pin in place.

LAIL11TL0531A0A

13. Place a calibrator gauge into the differential housing. 14. Move the planetary gear on the left-hand side in order to establish perfect contact with the satellite. Then push against the differential housing and take the clearance reading on the calibration gauge. Call this measurement Gs.

LAIL11TL0058A0A

CUIL15TR00124AA

15. Repeat the above operation to measure the clearance on the right-hand side, in the other planetary gear. Call this measurement Gd. Thus the shim to be installed in the differential housing is determined by: â&#x20AC;˘ Ss = Gs - 0.30 mm for the planetary gear on the left-hand side â&#x20AC;˘ Sd = Gd - 0.30 mm for the planetary gear on the right-hand side 16. Install the calculated shims and use a calibrating gauge following the procedures described above, checking if the planetaries on the RH and LH sides attained the correct play.

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Rear axle system - Rear bevel gear set and differential

Differential - Install Prior operation: Differential - Gear tooth contact (27.106). Prior operation: Bevel pinion - Preload (27.106)

Adjusting the conical pair CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Adjusting the differential bearing pre-load and checking the play between the pinion teeth and crown. Proceed as follows: 1. After assembling the pinion, assemble the complete differential set. 2. Fasten the support on the right-hand side and left-hand side (1) in the transmission box. Tighten three bolts 120 ° to a torque of 56 N (13 lb).

LAIL11TL0532A0A

LAIL11TL0533A0A

LAIL11TL0534A0A

3. Install the adjustment nuts on the RH and LH support. 4. Use tool 380000253 (2) to adjust the nuts (1) gradually and alternately while turning the differential so as to allow the bearings to settle.

5. Use a calibration gauge (1) to check the clearance between the teeth of the pinion and ring gear. 6. Take three measurements at 120 ° and calculate the arithmetic mean. Compare this mean with the recommended clearance: • Clearance between teeth: 0.18 - 0.23 mm. Average: 0.21 mm.

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Rear axle system - Rear bevel gear set and differential

7. Tighten the adjustment nuts equally to obtain a tightening torque of 9.8 - 14.7 NÂˇm (7 - 11 lb ft). 8. Measure the torque with a dynamometer (1) and some string around the flange of the differential case, which corresponds to a force on the dynamometer of 98.0 147.0 N (22.0 - 33.0 lb). NOTE: The differential conical bearings must be lubricated with SAE 10W30 oil. The values informed are in movement, therefore, the initial force (starting) is not to be considered.

LAIL11TL0535A0A

LAIL11TL0653A0A

9. Fit the lock plate (1) back on the bearing supports. Apply the thread lock sealant Loctite 274 to both bolts.

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Rear axle system - Rear bevel gear set and differential

Differential lock - Adjust Prior operation: Differential - Install (27.106).

Adjusting the position of the hitch sleeve of the differential lock â&#x20AC;&#x201C; Mechanical version CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Proceed as follows: 1. Install the differential disconnect device. 2. Insert an 8.00 mm (0.31 in) shim (2) between the sleeve and the case of the differential so that the surfaces of the sliding sleeve touch the box. 3. Use a lever to place the sleeve in contact with the 8.00 mm (0.31 in) shim and the case of the differential acting on the fork (1) on the positioned gauge.

LAIL11TL0536A0A

LAIL11TL0537A0A

4. Use a feeler gauge (1) to measure the clearance between the camshaft (2) and the seat on the shaft (3). 5. Position the required shim under the differential disconnect device.

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Rear axle system - Rear bevel gear set and differential

Differential lock - Adjust Prior operation: Differential - Install (27.106)

Adjusting the position of the hitch sleeve of the differential lock â&#x20AC;&#x201C; Electrohydraulic version CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Proceed as follows: 1. Install the plate without the adjustment shim. 2. Insert an 8 mm shim (2) between the sleeve and the case of the differential so that the surfaces of the sliding sleeve touch the box. 3. Use a lever to move the fork (1) until the sleeve is seated in the 8 mm shim

LAIL11TL0536A0A

LAIL11TL0538A0A

4. Use a feeler gauge (1) to measure the clearance between the plate (2) and its seat on the shaft (3). 5. Position the required shim under the plate (2).

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Rear axle system - Rear bevel gear set and differential

Differential lock mechanical control - Adjust Adjusting the differential lock control pedal travel On platform models, the distance (H1) between the end of pedal travel and the top part of the carpet must be 40.00 mm (1.57 in) to ensure that the differential lock sleeve engages. If that does not happen, proceed as follows: 1. Remove the cotter pin and disassemble the articulated pin (6) on the fork (5). 2. Loosen the cotter nut (4) and nut (2), and the corresponding lock nut inside the fork (1). 3. Tighten or loosen the tensioner (3) and the fork (5) until the differential lock control pedal is at the recommended height from the top of the carpet. 4. Tighten the nut (2) and the corresponding lock nut inside the fork (1). 5. Fasten the articulated pin (6) with the cotter pin.

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LAIL11TL0539A0A

Rear axle system - Rear bevel gear set and differential

Differential - Troubleshooting Problem Possible Cause The transmission Incorrect adjustment of the conical pinion produces excessive and/or differential bearings noise when the tractor is moving, even with the gear box in neutral (not originating from the side shaft ends) Incorrect adjustment or worn planetaries and satellites

The transmission produces excess noise when the tractor is loaded or unloaded

Excess gap between the semi-shaft and planetary Excess gap between the pinion and crown teeth

Inner component broken or defective

The transmission makes excessive noise and the set overheats

Insufficient play on the pinion and/or differential bearings

Insufficient play between the pinion and crown teeth

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Correction Disassemble the rear differential. Adjust the pinion and the bearings of the differential correctly. Consult the procedures in Bevel pinion - Depth adjust (27.106).

Disassemble the differential. Replace the worn parts. Adjust the differential gears correctly. Consult the procedures in Differential - Gear tooth contact (27.106). Disassemble the differential and replace the damaged parts Disassemble and adjust the pinion and the differential correctly. Consult the procedures in Bevel pinion - Depth adjust (27.106). Disassemble and replace the worn parts and adjust the clearance between the pinion and the crown correctly. Consult the procedures in Differential - Install (27.106). Disassemble and adjust the pinion and the differential bearings correctly. Consult the procedures in Bevel pinion - Depth adjust (27.106). Disassemble the rear transmission and adjust correctly. Consult the procedures in Differential - Gear tooth contact (27.106).

Index Rear axle system - 27 Rear bevel gear set and differential - 106 Bevel pinion - Depth adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Bevel pinion - Preload . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Gear tooth contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock control valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Differential lock mechanical control - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Rear axle system - 27 Planetary and final drives - 120

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Contents Rear axle system - 27 Planetary and final drives - 120

TECHNICAL DATA Planetary final drive General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Final drive housing Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SERVICE Planetary final drive Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Final drive housing Final drive housing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

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CONSUMABLES INDEX Consumable Loctite® 515™

Reference Final drive housing - Service instruction

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PAGE 27.3 / 10

Rear axle system - Planetary and final drives

Planetary final drive - General specification TL60E TL75E TL85E TL95E Type Epicycle with three straight-toothed cylindrical planetary gears Reduction ratio 14:78 = 1:5.57 13:78=1:6 Thickness of the thrust washers (8). 1 mm Thickness of the shims for adjusting the axial 4.5 mm - 4.6 mm - 4.7 mm - 4.8 mm - 4.9 mm - 5.0 mm - 5.1 mm clearance (10)* 5.2 mm - 5.3 mm - 5.4 mm - 5.5 mm - 5.6 mm - 5.7 mm - 5.8 mm (*) See the references in Final drive housing - Sectional view (27.120).

Planetary final drive - Special tools Tool 380001113 to be manufactured to disassemble and repair the side shaft ends and used together with 50114. (Values in mm) Use Ap 42 D. Use hardened tempered C 40 steel to build two rods

LAIL11TL0982F0A

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Rear axle system - Planetary and final drives

Tool 50114 to be manufactured to disassemble and repair the side shaft ends and used together with tool 380001113. (Values in mm) Use Fe 42 C to build â&#x20AC;&#x201C; (*) values to be determined according to the service jack seat.

LAIL11TL0983F0A

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Rear axle system - Planetary and final drives

Final drive housing - Sectional view Cross-section of the transmission

LAIL11TL0980F0A

A = 8 mm. Differential lock hitch sleeve travel. G = 0.2 - 0.4 mm . Final shaft axial play 1. 2. 3. 4. 5. 6. 7. 8. 9. 10.

Differential bearing support Differential lock activation fork Differential casing Satellite shim Satellites Differential lock spring Differential bearing support Reducer gear shim Differential output half-shaft End shaft axial play adjustment shim

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

End shaft Retainer Final reduction gear support Final reduction planetaries Bearing Planetary gear play adjustment shim Planetary Ring gear Satellite pins (5) Differential lock engagement sleeve Differential bearing pre-load adjustment shims

NOTE: During assembly, apply anaerobic sealant to the surfaces marked with an â&#x20AC;&#x153;Xâ&#x20AC;? in Mechanical transmission Service instruction (21.114).

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Rear axle system - Planetary and final drives

Final drive housing - Sectional view Cross-section of the transmission

LAIL11TL0981F0A

A = 8 mm. Differential lock hitch sleeve travel. G = 0.2 - 0.4 mm. End shaft axial play. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

Differential bearing support Differential lock activation fork Differential casing Satellite shims Satellites Differential lock spring Differential bearing support Reducer gear shim Differential output half shaft End shaft axial play adjustment shim End shaft

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

Retainer Reduction gears support Final drive planetary gears Spacer Bearing Planetary gear play adjustment shim Planetary Ring gear Satellite pins (5) Differential lock engagement sleeve Differential bearing pre-load adjustment shims

NOTE: During assembly, apply anaerobic sealant to the surfaces â&#x20AC;&#x153;X,â&#x20AC;? as shown in Mechanical transmission - Service instruction (21.114).

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Rear axle system - Planetary and final drives

Planetary final drive - Disassemble Prior operation: Final drive housing - Disassemble (27.120). With the set separated, proceed as follows: 1. Remove the retaining ring (1). 2. Remove the pins and remove the gears complete with the bearings.

LAIL11TL0547A0A

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Rear axle system - Planetary and final drives

Planetary final drive - Assemble Prior operation: Planetary final drive - Disassemble (27.120) 1. Fit all of the end parts of the epicyclical shaft. 2. Insert the gears complete with the bearings and the respective pins. 3. Insert the retaining ring (1).

LAIL11TL0547A0A

Next operation: Final drive housing - Assemble (27.120) .

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Rear axle system - Planetary and final drives

Final drive housing - Service instruction

LAIL11TL1051G0A

Diagram for application of anaerobic sealant in the installation of brake assembly and side final drives in the transmission box. The use of anaerobic sealant is recommended LOCTITEÂŽ 515â&#x201E;˘.

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Rear axle system - Planetary and final drives

Final drive housing - Disassemble Prior operation: Transmission housing - Drain fluid (21.114) .

1. Remove rear wheels. Consult the procedures in Rear wheels - Remove (44.520). 2. Raise the cab. Consult the procedures in Cab - Raise (90.150). 3. Place the tools 50114 and 380001113 (1) on the lateral edge of the rear axle case and place a service jack on the tool. Loosen the fixing bolts and remove the final drive housing.

LAIL11TL0540A0A

LAIL11TL0541A0A

LAIL11TL0542A0A

4. Position the final drive housing on a mobile workbench.

5. Loosen the bolt securing the driven gear support (1) on the wheel drive shaft and remove the safety lock.

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Rear axle system - Planetary and final drives

6. Remove the driven gear support (1) and remove the support axial play adjustment shim.

LAIL11TL0543A0A

LAIL11TL0544A0A

LAIL11TL0545A0A

7. Use a suitable extractor to remove the wheel drive shaft.

8. Remove the retainer (1).

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Rear axle system - Planetary and final drives

Final drive housing - Assemble 1. Fit the retainer with an adequate backstop. 2. Fit the driven gears support and its adjustment shim.

CUIL15TR00174AA

LAIL11TL0542A0A

LAIL11TL0546A0A

LAIL11TL0981F0A

3. Assemble the safety lock and tighten the support bolt (1) to the recommended torque.

4. Use a calibration gauge (1) to check if the axial clearance of the support (2) is 0.2 - 0.4 mm.

5. If the value is not within specifications, change the adjustment shim (10) until you have obtained the specified value. 6. Clean the mating surface between the final drive housing and the rear transmission. Apply anaerobic sealant to the surfaces indicated in Final drive housing - Service instruction (27.120). 7. Install the bolts for fixing the final reduction housing to the rear transmission.

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Index Rear axle system - 27 Planetary and final drives - 120 Final drive housing - Service instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Final drive housing - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary final drive - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary final drive - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary final drive - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Planetary final drive - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Power Take-Off (PTO) TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Power Take-Off (PTO) - 31

[31.104] Rear electro-hydraulic control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.1 [31.110] One-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.2 [31.114] Two-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.3 [31.116] Three-speed rear Power Take-Off (PTO) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31.4

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™ Loctite® 515™

Reference Two-speed rear Power Take-Off Three-speed rear Power Take-Off Three-speed rear Power Take-Off

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Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

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Contents Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104

FUNCTIONAL DATA Rear electro-hydraulic control Rear electro-hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Power Take-Off (PTO) clutch oil supply line Component identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

SERVICE Power Take-Off (PTO) clutch oil supply line Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

DIAGNOSTIC Rear electro-hydraulic control Rear electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description Independent Power Take-Off (PTO) disengaged Moving the lever (1) into position (E) makes the control connection move the control rod (4), figure 2, into the position shown below. With the rod (4) in this position and the solenoid unenergized, the hydraulic diagram of the control valve is as shown in figure 2.

LAIL11TL0680A0A

The line (11) receives a pressurized oil flow from the pump, and the rod (4) allows the pressurized oil to flow to the solenoid (1). When the solenoid (1) is unenergized, the transportation line to the Power Take-Off (PTO) clutch engagement cylinder (2) remains connected to the return line (10) while the supply line for the clutch brake (3) is open. In these conditions, the PTO clutch stays disengaged and the clutch brake stays engaged. The hydraulic diagram described in Rear electro-hydraulic control - Hydraulic schema (31.104) makes this operation phase clearer. The supply line is discharged, therefore the lubrication control valve allows only the lubrication of the rear bearing of the clutch (3). The pressurized oil that reaches the line (11) remains available for the operation of the lines (8) and (9). The situation shown in the diagram occurs when the solenoids (5) and (6) are unenergized. When the solenoid (5) is unenergized, the supply line (9) is discharged and thus the front wheel drive is engaged. When the solenoid (6) is unenergized, the supply line (8) is discharged and thus the rear differential lock is disengaged.

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Power Take-Off (PTO) - Rear electro-hydraulic control

CUIL13TR00628AA

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

Solenoid that controls the oil supply to the PTO clutch or to the clutch brake (not energized) Supply line (discharge) to PTO clutch engagement cylinder Supply line (pressurised) to clutch brake Position assumed by the rod (4) when the selector lever is in the position (E) Solenoid that controls the disengagement of the front wheel drive Solenoid that controls the engagement of the front and rear differential lock

Control valve block

Supply line discharge (the front and rear differential lock is disengaged) Supply line discharge (front wheel drive)

10.

Return line to transmission box

11.

Supply line from the pump to the hydraulic operation control valve (7)

12.

Oil under pressure

13.

Discharge oil

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description The Power Take-Off (PTO) installed on the tractor transfers motion to the transported or towed implements. It can be controlled: â&#x20AC;˘ Directly by the engine flywheel; â&#x20AC;˘ Synchronized with the transmission case;

Independent Power Take-Off (PTO) engaged Image 1 represents the situation of the hydraulic system when the selector lever for the operation mode of the PTO is in neutral and the solenoid (1) is energized. The line (11) receives pressurized oil from the pump and the control valve (4) allows the pressurized oil to flow to the solenoid (1). When the solenoid (1) is energized, the supply line to the clutch engagement cylinder of the PTO (2) is pressurized, while the supply line to the clutch brake (3) is connected to the return line (10). In these conditions, the PTO is engaged and the clutch brake is disengaged. With the solenoid valve (1) deactivated, the supply line to the PTO clutch engagement cylinder (2) is discharged and connected to the line (10), while the supply line to the clutch brake (3) remains pressurized. Under these conditions the PTO clutch is disengaged and the clutch brake is engaged. The hydraulic diagram described on Rear electro-hydraulic control - Hydraulic schema (31.104) represents this operation phase. The pressurized oil in the line (11) is also available for the operation of the lines (8) and (9). The figure shows the situation when the solenoids (5) and (6) are energized. When the solenoid (5) is energized, the supply line (9) is pressurized and thus the front wheel drive is disengaged. With the solenoid (6) energized, the supply line (8) is pressurized, and the rear differential lock engages. With solenoid valve (5) deactivated, the supply line (9) is discharged and the front wheel drive engages. With solenoid valve (6) deactivated the supply line (8) is discharged, with the relative disengagement of the front and rear differential lock.

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Power Take-Off (PTO) - Rear electro-hydraulic control

CUIL15TR00110GA

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

Solenoid that controls the oil supply to the PTO clutch or to the clutch brake (energized). Supply line (pressurized) to PTO clutch engagement cylinder. Supply line (discharge) to clutch brake.

Control valve block.

Pressurized supply line (rear differential lock engaged). Pressurized supply line (front wheel drive disengaged). Return line to transmission box.

10. Position assumed by the rod when the PTO selector lever is in neutral. Solenoid that controls the disengagement of the 11. front wheel drive. Solenoid that controls the engagement of the rear 12. differential lock. 13.

Supply line from the pump to the hydraulic operation control valve (7). Oil under pressure. Discharge oil.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Dynamic description Power Take-Off (PTO) synchronized with the transmission

CUIL15TR00111GA

When the PTO is synchronized with the gearbox, the control valve rod (4) will be in the position shown in figure 1. The line (11) receives pressurized oil from the pump, but the rod (4) closes the passage to the PTO clutch engagement piston supply lines (2) and to the clutch brake (3), connecting them to the line (10), as shown in the figure. The pressurised oil in the line (11) is available for the operation of lines (8) and (9). The figure shows the situation when the solenoids (5) and (6) are energized. With the solenoid (5) energized, the supply line (9) is pressurized, and the front wheel drive disengages. With the solenoid (6) energized, the supply line (8) is pressurized, and the rear differential lock engages.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Figure legend 1. 2. 3. 4. 5. 6.

Solenoid that controls the oil supply to the PTO clutch or to the clutch brake (not energized) Supply line (discharge) to PTO clutch engagement cylinder Supply line (discharge) to clutch brake Position of the rod when synchronized PTO is selected Solenoid that controls the disengagement of the front wheel drive Solenoid that controls the engagement of the rear differential lock

Control valve block

Pressurized supply line (rear differential lock engaged) Pressurized supply line (front wheel drive) Return line to transmission box

9. 10. 11. 12.

Supply line from the pump to the hydraulic operation control valve (7). Oil under pressure

13.

Discharge oil

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Hydraulic schema Operation - Power Take-Off (PTO) clutch off and safety brake on

CUIL15TR00112GA

The control valve directs pressurized oil through the gallery (4) to the piston of the hydraulic safety brake (1). Oil remains in the clutch drive line (12). The lubrication control valve (8) remains up since there is no pressure acting on the valve, and also due to the action of the spring. Thus, the lubrication flow (13) directed to the PTO assembly is limited to keep the rear bearing of the clutch lubricated.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Legend Figure 1 Reference

Component

Reference

(1)

PTO safety brake piston

(6)

(2)

Calibrated orifice of the PTO piston: provides a small flow of oil to lubricate and cool the friction disks with the PTO engaged

(7)

(3)

Disks of the PTO hydraulic clutch

(8)

(4)

Oil inlet gallery to the safety brake piston

(9)

(5)

PTO clutch lubrication drain line

(10)

(11) (13)

Oil under pressure Lubrication flow

(12)

Component Accumulator piston, whose function is to soften the coupling of the PTO, mainly when under load (high drag torque) Oil inlet gallery to the actuation circuit for the PTO clutch, passing through the accumulator Lubrication control valve for the bearings and clutch of the PTO: controls the flow during PTO clutch coupling Oil inlet gallery to the lubrication circuit for the clutch and bearings of the PTO Lubrication relief valve (bearings and clutch): 5 - 8 bar Without oil flow

Operation â&#x20AC;&#x201C; PTO clutch on and safety brake off The control valve interrupts the flow of oil to the brake piston (1). There is no flow (13) in the line (4). The clutch drive line now has oil pressure (12). This compresses the PTO clutch disks and transmits the motion to the output shaft. The accumulator, along with the restrictor mounted on the clutch drive line, ensures the clutch coupling is gradual and smooth. The lubrication control valve (8) is forced down by the action of the pressure acting on the valve, overcoming the action of the spring. Thus, the lubrication flow (14) from the gallery (9) is directed to the PTO assembly through the line. This lubricates the entire PTO clutch assembly and the front and rear bearings.

Legend Figure 2 Reference

Component

Reference

(1)

PTO safety brake piston

(6)

(2)

Calibrated orifice of the PTO piston: provides a small flow of oil to lubricate and cool the friction disks with the PTO engaged

(7)

(3)

Disks of the PTO hydraulic clutch

(8)

(4)

Oil inlet gallery to the safety brake piston

(9)

(5)

PTO clutch lubrication drain line

(10)

(11) (13)

Drive Shaft No flow

(12) (14)

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Power Take-Off (PTO) - Rear electro-hydraulic control

CUIL15TR00113GA

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) clutch oil supply line - Component identification (1). Power Take-Off (PTO) clutch drive line. (2). PTO safety brake line. (3). PTO clutch lubrication line. (4). Location of the pressure regulating valve. Pressure of 16 - 18 bar.

CUIL13TR00802AA

CUIL13TR00793AA

CUIL13TR00818AA

(1). Accumulator. Provides a smooth PTO start-up. (2). Calibrated hole restrictor. (3). Pressure regulating valve for lubrication of the PTO, located on the inlet gallery of the lubrication line. (4). Lubrication control valve for the bearings and PTO clutch.

(1). PTO safety brake piston.

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Power Take-Off (PTO) - Rear electro-hydraulic control

Power Take-Off (PTO) clutch oil supply line - Pressure test CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

Tests on the hydraulic circuit of the Power Take-Off (PTO) Before performing hydraulic adjustments and tests: • Analyse and understand the hydraulic flow of the different functions and circuits. • Make sure that the oil level is correct. • Make sure of the correct specification of oil used. • Make sure of the good condition of the system's oil filter. If necessary, replace the filter. NOTE: All tests and adjustments must be conducted with an oil temperature of at least 50.0 °C (122.0 °F).

Leak test on the safety brake of the Power Take-Off (PTO) The tests described herein must be performed after the tests described in Regulated/Low pressure system Pressure test (35.322). Carry out the following procedures: 1. Park the machine on a level and hard surface. 2. Install the pressure gauge 380000552 with a pressure scale between 0.0 - 40.0 bar (0.0 - 580.0 psi) on the fitting (1). 3. Start the engine. 1500 RPM.

Adjust the engine speed to

CUIL13TR00824AA

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Power Take-Off (PTO) - Rear electro-hydraulic control

4. Make sure that the selector valve (X) is open (positioned upward).

CUIL13TR00802AA

CUIL13TR00774AA

CUIL13TR00802AA

5. Make sure that the electrohydraulic differential lock is disengaged. The solenoid (1) will be de-energized. 6. Make sure that the Auxiliary Front Wheel Drive (FWD) is engaged. The solenoid (2) will be de-energized. 7. Make sure the Power Take-Off (PTO) is off. The solenoid (3) will be de-energized, releasing the flow of oil to the PTO brake. 8. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi). 9. If the pressure is incorrect, service the PTO brake mechanism, seeking to eliminate likely pressure leaks through the piston. See the sequence of procedures described in Three-speed rear Power Take-Off (PTO) - Remove â&#x20AC;&#x201C; Electrohydraulic version (31.116). 10. If the pressure is correct, proceed with the leak tests indicated below.

Leak test of the Power Take-Off (PTO) clutch With the pressure gauge still installed, perform the following procedures: 1. Make sure that the selector valve (1) is open (positioned upward).

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Power Take-Off (PTO) - Rear electro-hydraulic control

2. Make sure that the electrohydraulic differential lock is disengaged. The solenoid (1) will be de-energized. 3. Make sure that the Auxiliary Front Wheel Drive (FWD) is engaged. The solenoid (2) will be de-energized. 4. Make sure that the Power Take-Off (PTO) is engaged. The solenoid (3) will be energized, releasing the flow to the piston of the PTO clutch. 5. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi). 6. If the pressure is incorrect, service the PTO clutch, seeking to eliminate likely pressure leaks through the internal and external piston seals. See the sequence of procedures described in Three-speed rear Power Take-Off (PTO) - Remove â&#x20AC;&#x201C; Electrohydraulic version (31.116).

CUIL13TR00774AA

CUIL13TR00793AA

7. Service the accumulator (1), seeking to eliminate likely pressure leaks through the piston. 8. Check the operation and for wear of the control valve piston (2). 9. If the pressure is correct, perform the leak tests described below.

Testing the lubrication pressure regulating valve of the Power Take-Off (PTO) clutch 1. Install the pressure gauge 380000552 with a pressure scale between 0.0 - 40.0 bar (0.0 - 580.0 psi) on the fitting (1) for the lubrication oil inlet.

CUIL13TR00824AA

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Power Take-Off (PTO) - Rear electro-hydraulic control

2. Make sure that the selector valve (1) is open (positioned upward).

CUIL13TR00802AA

CUIL13TR00774AA

3. Make sure that the electrohydraulic differential lock is disengaged. The solenoid (1) will be de-energized. 4. Make sure that the Auxiliary Front Wheel Drive (FWD) is engaged. The solenoid (2) will be de-energized. 5. Make sure the Power Take-Off (PTO) is engaged. The solenoid (3) will be energized, releasing the flow to the clutch piston as well as to the lubrication points of the assembly. 6. The pressure indicated on the pressure gauge should be 5.0 - 8.0 bar (72.5 - 116.0 psi).

7. If the pressure is incorrect and supposing that there is no pressure leak from the PTO clutch assembly, replace the valve (1). 8. If the pressure is correct, this means there is no irregularity in the system. 9. Remove the pressure gauge from the fitting.

CUIL13TR00793AA

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Power Take-Off (PTO) - Rear electro-hydraulic control

Rear electro-hydraulic control - Troubleshooting Problem Possible Cause Direct drive PTO (driven Insufficient oil in the transmission from the engine flywheel) does not start Clogged oil filter

The PTO direct drive (driven from the engine flywheel) cannot disengage

Power Take-Off (PTO) clutch does not stop (partially drags).

Correction Top up the oil. Consult the procedures in Transmission housing - Filling (21.114).

Replace the filter. Refer to the Operatorâ&#x20AC;&#x2122;s Manual. Hydraulic pump failure Service or replace the pump. Failure in the engagement switch for the Replace the switch. Power Take-Off (PTO). Failure in the current supply to the solenoid: Re-establish the electrical connection and loose, damaged or faulty connections. replace the damaged parts The solenoid that controls the PTO clutch Service or replace the solenoid is stuck in the drive position of the clutch brake. Oil leaking through the seals causing a Replace any faulty seals pressure drop: manifold seal, piston, etc. Failure in the Power Take-Off (PTO) switch Replace switch

Failure in the current supply to the solenoid: loose, damaged or faulty connections. The solenoid that controls the PTO clutch is stuck in the clutch supply position. PTO switch failure

Re-establish the electrical connection and replace the damaged parts Service or replace the solenoid

Failure in the current supply to the solenoid: loose, damaged or faulty connections. The solenoid that controls the PTO clutch brake is stuck in the clutch supply position. Wear of the PTO clutch brake

Re-establish the electrical connection and replace the damaged parts Service or replace the solenoid

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Replace switch

Replace the clutch break

Index Power Take-Off (PTO) - 31 Rear electro-hydraulic control - 104 Power Take-Off (PTO) clutch oil supply line - Component identification . . . . . . . . . . . . . . . . . . . . . . . .

Power Take-Off (PTO) clutch oil supply line - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear electro-hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear electro-hydraulic control - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear electro-hydraulic control - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear electro-hydraulic control - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Power Take-Off (PTO) - 31 One-speed rear Power Take-Off (PTO) - 110

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Contents Power Take-Off (PTO) - 31 One-speed rear Power Take-Off (PTO) - 110

TECHNICAL DATA One-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 General specification â&#x20AC;&#x201C; Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA One-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO)

One-speed rear Power Take-Off (PTO) - General specification 540 RPM Power Take-Off (PTO) Type Engagement and control Power available at PTO Turning direction viewed from the rear of the tractor Engine speed with the PTO at 540 RPM PTO speed with the engine at maximum power Speed with PTO synchronized with the gearbox - 30 km/h transmission Bearing position shaft diameter Sprocket terminal shaft diameter

TL60E TL75E TL85E TL95E Independent of tractor speed or synchronized with gearbox Mechanical using levers located on the left-hand side of the operator's position 43.2 kW 50.0 kW 56.7 kW 61.5 kW (58.7 Hp) (68.0 Hp) (77.1 Hp) (83.6 Hp) Clock Wise 2199 RPM 614 RPM 8.2 RPM/wheel speed

8.9 RPM/wheel speed 49.938 - 50.000 mm 1 3/8 in (6 teeth)

One-speed rear Power Take-Off (PTO) - General specification â&#x20AC;&#x201C; Electrohydraulic version 540 RPM Power Take-Off (PTO) Type

Engagement and control

Turning direction (viewed from the rear of the tractor) Engine rpm with PTO at 540 RPM PTO speed with engine at full power ( 2500 RPM) PTO speed when synchronised with the gearbox ( 30 km/h version) Diameter of the controlled shaft at the rear bearing Diameter of the controlled shaft at the front bearing Diameter of the splined output shaft

TL75E TL85E TL95E Regardless of the speed allowed by the soil, driven directly from the engine or synchronized with the gearbox, driven from the output shaft of the gearbox Electro-hydraulic/mechanical, hitch mount through the control knob and manual lever. Mechanical command, through a manual lever located on the right-hand side of the operator seat Clock Wise 2200 RPM 614 RPM 8.2 RPM

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8.9 RPM 39.984 - 40.000 mm 39.984 - 35.000 mm 1 3/8 in (6 splines)

Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO)

One-speed rear Power Take-Off (PTO) - Torque

CUIL13TR00624AA

Reference (1) (2) (3)

Components Fixing bolts for the bearing support Fixing bolts for the PTO case PTO protection fixing bolts Fixing nut for the bearing shaft:

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Turnbuckle M12 x 1.25 M16 x 1.5 M8 X 1.25 M32 x 1.5

Torque value 98 N路m (72 lb ft) 221 N路m (163 lb ft) 25 N路m (18 lb ft) 294 N路m (217 lb ft)

Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO)

One-speed rear Power Take-Off (PTO) - Sectional view

CUIL13TR00626AA

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

Component Drive gear Bearing Locating pin PTO fixing bolt

Reference (6) (7) (8) (9)

(5)

Fixing bolts for the PTO guard

(10)

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Component Power Take-Off (PTO) shaft Bearing Locking ring Driven Gear Surface for application of the anaerobic sealant

Power Take-Off (PTO) - One-speed rear Power Take-Off (PTO)

One-speed rear Power Take-Off (PTO) - Sectional view

CUIL15TR00171GA

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

Component Transmission shaft from gearbox Locking ring Bearing thrust washer Transmission shaft from engine flywheel

(5)

PTO clutch (driven by the shaft (4)

Reference (6) (7) (8) (9)

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Component PTO splined output shaft Spacer Driven gear Driven gear shaft NOTE: Apply sealant to the surface "X" during assembly.

Index Power Take-Off (PTO) - 31 One-speed rear Power Take-Off (PTO) - 110 One-speed rear Power Take-Off (PTO) - General specification â&#x20AC;&#x201C; Electrohydraulic version . . . . . . . .

One-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

One-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

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Contents Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114

TECHNICAL DATA Two-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Two-speed rear Power Take-Off (PTO) Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Two-speed rear Power Take-Off (PTO) Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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CONSUMABLES INDEX Consumable Loctite® 515™

Reference Two-speed rear Power Take-Off

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PAGE 31.3 / 15

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - General specification 540 RPM/ 540E RPM Power Take-Off (PTO) Type Engagement and control

TL60E TL75E TL85E TL95E Independent of tractor speed or synchronized with gearbox Mechanical using levers located on the left-hand side of the operator's position

Turning direction viewed from the rear of the tractor Engine speed with the PTO at 540 RPM Engine speed with the PTO at 540E RPM PTO speed with the engine at maximum power at 2500 RPM - 540 RPM Speed with PTO synchronized with the 8.2 RPM/wheel gearbox - 30 km/h - 540 RPM transmission speed Speed with PTO synchronized with the 10.51 RPM/ gearbox - 30 km/h - 540E RPM transmission wheel speed Sprocket terminal shaft diameter

Clock Wise 2199 RPM 1715 RPM 614 RPM 8.9 RPM/wheel speed 11.14 RPM/wheel speed 1 3/8 in (6 teeth)

Two-speed rear Power Take-Off (PTO) - Special tools Special tools NOTICE: The operations described in this section should only be performed using the essential tools which appear below with the symbol (X). However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section. Use a hook with adequate capacity to lift the Power Take-Off (PTO) housing. Use guide pins suitable for removing/installing the PTO cover.

Two-speed rear Power Take-Off (PTO) - Torque Reference (1) (2) (3)

Component Fixing bolts for the bearing support Self-locking nuts for securing the terminal Fixing bolts for the Power Take-Off (PTO) case Fixing nut for the bearing shaft

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Turnbuckle M12 x 1.25 M12 x 1.25 M16 x 1.5 M32 x 1.5

Torque value 98 N路m (72 lb ft) 162 N路m (119 lb ft) 221 N路m (163 lb ft) 294 N路m (217 lb ft)

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

CUIL13TR00625AA

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Sectional view

CUIL13TR00627AA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Locating pin PTO fixing bolt Bearing Terminal self-locking nut Terminal 540E RPM Terminal 540 RPM Retainer Bearing Locating pin

Reference (10) (11) (12) (13) (14) (15) (16) (17) (18)

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Component Rear transmission box Rear transmission support Controlled shaft fixing nut Driven gear support bushings Fixed gear Hitch sleeve 540E RPM rotation driven gear Dual gear 540 RPM rotation driven gear

Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Disconnect the negative battery cable from the battery. 2. Remove the third point link (1).

LAIL11TL0666A0A

LAIL11TL0667A0A

LAIL11TL0670A0A

3. Remove the towing hook (1) - When available.

4. Remove the draw bar (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. Remove the six fastening bolts from the towing hook support (1). 6. Drain the oil from the transmission. Consult the procedures in Transmission housing - Drain fluid (21.114).

LAIL11TL0671A0A

LAIL11TL0673A0A

LAIL11TL0674A0A

LAIL11TL0675A0A

7. Remove the two upper bolts (1) which fasten the Power Take-Off (PTO) to the transmission.

8. Insert the two guide pins (1). Remove the two lower bolts (2) which fasten the PTO to the transmission.

9. Remove the return spring from the pins (1) and remove the PTO speed selection control cable.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

10. Remove the bolts which fasten the guard spline (1) to the PTO speed selection control cable coating.

LAIL11TL0676A0A

LAIL11TL0677A0A

11. Engage the selection lever for the operation mode of the PTO into the position for PTO synchronized with the gear box so that the hitch sleeve rests on the shaft during the disassembly operation. 12. Loosen the PTO a few centimeters and separate the PTO using the hook with a lifting chain (1) .

Next operation: Two-speed rear Power Take-Off (PTO) - Disassemble (31.114) .

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Disassemble Prior operation: Two-speed rear Power Take-Off (PTO) - Remove (31.114) . 1. Place the Power Take-Off (PTO) in a vise.

LAIL11TL0682A0A

LAIL11TL0683A0A

LAIL11TL0684A0A

2. Loosen the lock nut (1) fastening the controlled shaft parts.

3. Remove the controlled shaft nut (1).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

4. Remove the four fastening bolts from the inner PTO support (1).

LAIL11TL0685A0A

LAIL11TL0686A0A

LAIL11TL0687A0A

LAIL11TL0688A0A

5. Remove the fork rod bolt (1).

6. Remove the rear cover rod (1).

7. Partially remove the shaft (1) and the internal support (3) together with the camshaft (2), the bearings, the sleeve, and the PTO control fork. 8. Also remove the bearing thrust shim at the side of the driven gear (4) of the 540 RPM PTO.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

9. Remove the rear bearing thrust shim (1) and the jackshaft (2) together with the final shaft.

LAIL11TL0689A0A

LAIL11TL0690A0A

10. Remove the lock ring, the bearing (1) and the retainer (if it needs replacing) of the rear cover.

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Assemble CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

Prior operation: Two-speed rear Power Take-Off (PTO) - Disassemble (31.114) . 1. Mount the retainer, the rear bearing (1) and the lock ring on the rear cover.

LAIL11TL0690A0A

LAIL11TL0689A0A

LAIL11TL0688A0A

2. Install the driven shaft (2) with the adjustment shim (1). 3. Install the driven shaft gear, the fixed gear, the sleeve, the fork and the fork support rod.

4. Install the driven shaft gear (4). Install the inner cover with the camshaft (2).

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

5. Install the cover with the bolts (1). 6. Install the gear thrust shim of the 540 RPM PTO and install the bearing on the cover.

LAIL11TL0685A0A

LAIL11TL0686A0A

LAIL11TL0684A0A

7. Install the rod and secure with the bolt (1).

8. Tighten the driven shaft nut. Then lock the nut.

Next operation: Two-speed rear Power Take-Off (PTO) - Install (31.114) .

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Power Take-Off (PTO) - Two-speed rear Power Take-Off (PTO)

Two-speed rear Power Take-Off (PTO) - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Two-speed rear Power Take-Off (PTO) - Assemble (31.114) . 1. Clean the surface that connects the transmission and the Power Take-Off (PTO). Apply LOCTITEÂŽ 515â&#x201E;˘ anaerobic sealant as shown in the figure to the side. 2. Clean the PTO connection surface. 3. Raise the PTO housing and place the PTO housing in front of the transmission. Introduce the housing onto the guide pins for assembly.

LAIL11TL0678A0A

LAIL11TL0674A0A

LAIL11TL0676A0A

4. Remove the hook and remove the chain from the PTO housing. 5. Mount the lower bolts (2). Remove the guide pins (1). 6. Remove the upper bolts from the PTO housing.

7. Mount the guard spline (1) to the sheath of the cable for the speed selection control of the PTO. 8. Mount the control lever cable and install the pin and the return spring. 9. Assemble the draw bar support 10. Assemble the draw bar, the towing hook and the 3 point link bar. 11. Fill the transmission with oil. Consult the procedures in Transmission housing - Filling (21.114). 12. Connect the negative battery cable.

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Index Power Take-Off (PTO) - 31 Two-speed rear Power Take-Off (PTO) - 114 Two-speed rear Power Take-Off (PTO) - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Two-speed rear Power Take-Off (PTO) - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116

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Contents Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116

TECHNICAL DATA Three-speed rear Power Take-Off (PTO) General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Torque – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

FUNCTIONAL DATA Three-speed rear Power Take-Off (PTO) Three-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Three-speed rear Power Take-Off (PTO) - Sectional view – Electrohydraulic version . . . . . . . . . . . . . . . . 9 Three-speed rear Power Take-Off (PTO) - Sectional view – Electrohydraulic version . . . . . . . . . . . . . . . 11

SERVICE Three-speed rear Power Take-Off (PTO) Remove – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Install – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Power Take-Off (PTO) clutch brake Remove – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Install – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™

Reference Three-speed rear Power Take-Off Three-speed rear Power Take-Off

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PAGE 31.4 / 8 31.4 / 10

Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - General specification 540 RPM/ 750 RPM/ 1000 RPM Power Take-Off (PTO) Type Engagement and control

TL60E TL75E TL85E TL95E Independent of tractor speed or synchronized with gearbox Mechanical using levers located on the left-hand side of the operator's position

Turning direction viewed from the rear of the tractor Engine speed with the PTO at 540 RPM Engine speed with the PTO at 750 RPM Engine speed with the PTO at 1000 RPM PTO speed with the engine at maximum power at 2500 RPM - 540 RPM PTO speed with the engine at maximum power at 2500 RPM - 750 RPM PTO speed with the engine at maximum power at 2500 RPM - 1000 RPM Speed with PTO synchronized with the 8.2 RPM/wheel gearbox - 30 km/h - 540 RPM transmission speed Speed with PTO synchronized with the 10.51 RPM/ gearbox - 30 km/h - 750 RPM transmission wheel speed Speed with PTO synchronized with the 14.1 RPM/ gearbox - 30 km/h - 1000 RPM transmission wheel speed Sprocket terminal shaft diameter - 540 RPM and 750 RPM Sprocket terminal shaft diameter- 1000 RPM Outer diameter of the driven gear support bushes shaft Inner diameter of the driven gear Play between driven gears Diameter of the front and center driven shaft bushings Diameter of the rear driven shaft bushing Inner diameter of the front and central bushings Inner diameter of the rear bushing Play between the shaft and the front and central bushings Play between the shaft and the rear bushing

Clock Wise 2199 RPM 2382 RPM 2381 RPM 614 RPM 787 RPM 1050 RPM 8.9 RPM/wheel speed 11.14 RPM/wheel speed 15.2 RPM/wheel speed 1 3/8 in (6 teeth) 1 3/8 in (12 teeth) 49.925 - 49.250 mm 50.050 - 50.089 mm 0.100 - 0.164 mm 39.166 - 39.191 mm 34.984 - 35.000 mm 39.200 - 39.239 mm 35.009 - 35.048 mm 0.009 - 0.073 mm 0.009 - 0.064 mm

Three-speed rear Power Take-Off (PTO) - General specification 540 RPM/ 750 RPM/ 1000 RPM Power Take-Off (PTO) TL75E Engine speed with PTO speed at 540 RPM Engine speed with PTO speed at 750 RPM Engine speed with PTO speed at 1000 RPM PTO speed with engine at full power 2500 RPM - For 540 RPM PTO PTO speed with engine at full power 2500 RPM - For 750 RPM PTO PTO speed with engine at full power 2500 RPM - For 1000 RPM PTO PTO speed of 540 RPM synchronized with the gearbox PTO speed of 750 RPM synchronized with the gearbox PTO speed of 1000 RPM synchronized with the gearbox 47835583 21/10/2015

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TL85E 2200 RPM 2382 RPM 2381 RPM 614 RPM 787 RPM 1050 RPM 8.9 RPM 11.4 15.2

TL95E

Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

TL75E Diameter of the external output shaft - 540 RPM PTO Diameter of the external output shaft - 750 RPM PTO Diameter of the external output shaft - 1000 RPM PTO Outer diameter of the gear bushings (18)* and (21)*) Internal diameter of the gears (3)* and (19)* Clearance between the gears and bushings Diameter of the controlled shaft (22)* at the front and central bushings (18)* Diameter of the controlled shaft (22)* at the rear bushing (21)* Internal diameter of the front and central bushings (18)* Internal diameter of the rear bushing (21)* Clearance between the shaft (22)* and the front and central bushings (18)* Clearance between the shaft (22)* and the rear bushing (21)* Drive clutch disc (11)* Driven clutch disc (12)* Thickness of clutch drive plate (11)* Thickness of driven clutch disc Spring (10), clutch uncoupling (free length) Spring (10), clutch uncoupling (length under a load of 67.6 kg + 3.4 kg) Lubrication pressure relief valve spring (12)** with no load Lubrication pressure relief valve spring (12)** (length under a load of 8.1 kg + 0.4 kg) Lubrication pressure relief valve adjustment Valve (5)** spring (4)** for hitching of discs (11)* and (12)* and rear bearing lubrication (13)* (at free length) Spring (5)** under a load of 2.48 kg + 0.1 kg) Valve diameter (4)** Valve housing diameter (4)** Clearance between the valve (4)** and the housing Accumulator spring (14)** (free length) Accumulator spring (14)** (length under a load of 34.9 kg + 1.7 kg) Clearance between the rod (11) and the housing Clearance between the pressure relief valve and the housing Spring (18), pressure relief valve (with free length) Spring (18), pressure relief valve (length under a load of 29.17 kg + 1.30 kg) Relief valve pressure adjustment (20)

TL85E 1 3/8 in (6 splines) 1 3/8 in (6 splines) 1 3/8 in (21 splines) 49.925 - 49.950 mm 50.050 - 50.089 mm 0.100 - 0.164 mm

TL95E

39.166 - 39.191 mm 34.984 - 35.000 mm 39.200 - 39.239 mm 35.009 - 35.048 mm 0.009 - 0.073 mm 0.009 - 0.064 mm 5 units 5 units 1.95 - 2.05 in 1.70 - 1.80 in 58 mm 31 mm 29 mm 22 mm 4.4 - 5.9 Kg/cmÂ˛ (62.6 - 83.9 psi) 57 mm 36 mm 11.990 - 11.996 mm 12.016 - 12.030 mm 0.020 - 0.040 mm 122 mm 100 mm 0.025 - 0.035 mm 0.025 mm 127 mm 102.5 mm 12.2 - 13.2 bar (177 - 191 psi)

(*) See the references in Three-speed rear Power Take-Off (PTO) - Sectional view (31.116). (**) See the references in Three-speed rear Power Take-Off (PTO) - Sectional view â&#x20AC;&#x201C; Electrohydraulic version (31.116).

Three-speed rear Power Take-Off (PTO) - Special tools NOTICE: The operations described in this section should only be performed using the essential tools which appear below with the symbol (X). However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Use a hook with adequate capacity to lift the Power Take-Off (PTO) housing. Use guide pins suitable for removing/installing the PTO cover.

Three-speed rear Power Take-Off (PTO) - Special tools – Electrohydraulic version 380000243

Hi-Lo clutch spring compressor

Three-speed rear Power Take-Off (PTO) - Torque – Electrohydraulic version

LAIL11TL1035G0A

Reference (C1) (C2) 47835583 21/10/2015

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Torque value 294 N·m (217 lb ft) 25 N·m (18 lb ft)

Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Reference (C3) (C4) (C5) (C6)

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Torque value 25 N路m (18 lb ft) 221 N路m (163 lb ft) 55 N路m (41 lb ft) 98 N路m (72 lb ft)

Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view

LAIL11TL1043G0A

Reference (13) (14) (15) (16) (17) (18) (19) (20) (21)

Component Outer control lever Inner control device 750 RPM PTO coupling sleeve Controlled shaft fixing nut Controlled shaft Shieldings O-ring Control fork support rod PTO cover

(22)

Rod fixing bolt (20)

(11)

Component Camshaft Thrust washer Driven gears Thrust washer Retainer Driven gear bushes O-ring Washer Snap pin Coupling sleeve for the 540 RPM or 1000 RPM Power Take-Off (PTO) Spring

(23)

(12)

Ratchet

(X)

PTO fixing bolt Surface for application of LOCTITE® 515™ anaerobic sealant

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view â&#x20AC;&#x201C; Electrohydraulic version

LAIL11TL1036G0A

Reference (1) (2) (3) (4) (5) (6)

Component Controlled shaft fixing nut Hitch sleeve for 750 RPM PTO Gear for 750 RPM PTO Engine flywheel transmission shaft Gearbox transmission shaft Camshaft gear

Reference (13) (14) (15) (16) (17) (18)

(7)

Support for rear bearings

(19)

(8) (9)

Oil distribution manifold for piston (9) Gear connection piston Spring for disengaging the clutch discs (11) and (12)

(20) (21)

Component Rear clutch bearing Output shaft guard (15) PTO splined output shaft Pressure/return line to clutch brake (24) Retainer Front and middle bushings for gears (19) Front ( 1000 RPM) and central ( 540 RPM) gears PTO fixing bolts Driven gear rear bushing (3)

(22)

Controlled shaft

(10)

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Reference

Component

Reference

(11)

Clutch drive discs

(23)

(12)

Clutch driven disks

(24)

Component PTO clutch control piston pressure/return line (9) Clutch brake piston

NOTE: Apply LOCTITEÂŽ 515â&#x201E;˘ anaerobic sealant to the surface (X) during assembly.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Sectional view â&#x20AC;&#x201C; Electrohydraulic version

LAIL11TL1037G0A

Reference (1) (2) (3) (4) (5) (6) (7)

Component Support for rear bearings Conductor bolts Outlet valve for the cylinder Lubrication control valve (bearings and clutch) Spring for valve (4) External support to hold the PTO speed selection control cable PTO selection external control lever

Component Reference (8) Internal selector of the Power Take-Off (PTO) (9) Speed selection fork Lubricating oil connector (10) (11)

Lubricating pressure relief valve

(12)

Spring for valve (11)

(13)

Accumulator piston

(14)

Accumulator spring for gradual PTO engagement

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Remove â&#x20AC;&#x201C; Electrohydraulic version DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Disconnect the negative cable (1) from the battery.

CUIL13TRO0194AA

LAIL11TL0691A0A

LAIL11TL0693A0A

2. Remove the third point hitch bar (1). 3. Drain the oil from the transmission. Consult the procedures in Transmission housing - Drain fluid (21.114).

4. Insert lifting chains for the trailer hitch support (2). Remove the support bolts and remove the support.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

5. Remove the four fastening bolts (1) and the PTO protection.

LAIL11TL0694A0A

LAIL11TL0695A0A

LAIL11TL0696A0A

LAIL11TL0697A0A

6. Loosen the connections and separate the PTO line (1).

7. Disassemble the PTO cover (4), the front lock ring (3) and the clutch drive plate (2).

8. Remove the rear locking ring (1).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

9. Secure the PTO (1) to the lifting hook with the chains. 10. Put the load elevator under tension. Then remove the four bolts that secure the PTO transmission box to the rear axle. NOTE: Before removing the PTO completely, engage the PTO synchronized to the gearbox using the cab lever.

LAIL11TL0698A0A

Next operation: Three-speed rear Power Take-Off (PTO) - Disassemble â&#x20AC;&#x201C; Electrohydraulic version (31.116) .

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Disassemble – Electrohydraulic version Prior operation: Three-speed rear Power Take-Off (PTO) - Remove – Electrohydraulic version (31.116)

1. Secure the Power Take-Off (PTO) (1) in the vise. Separate the lifting hook and the chain. Unlock and remove the controlled shaft nut (2).

LAIL11TL0702A0A

LAIL11TL0703A0A

LAIL11TL0704A0A

2. Remove the Allen screw which secures the fork (1) rod (3) on the support (2).

3. Remove the rod (1) using a suitable punch.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

4. Remove the fork (2) and sleeve (1).

LAIL11TL0705A0A

LAIL11TL0706A0A

LAIL11TL0707A0A

LAIL11TL0708A0A

5. Remove the 750 RPM driven gear (1) and the thrust shim behind the gear.

6. Remove the lock ring (2) and remove the drive plate housing of the clutch with bearing (1).

7. Remove the outer housing of the clutch with the clutch discs (1).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

8. Remove the spring pin (1) that holds the external speed selection lever (2) using a hammer and a suitable punch, then remove the nuts.

LAIL11TL0709A0A

LAIL11TL0710A0A

9. Disassemble the lock rings (1) and (2) and control shaft (3) by hitting the end with a copper pin. Also disassemble the gear (4).

10. Remove the four bolts (1) which fasten the gear case (2). Remove the lock ring that holds the PTO outer shaft using pliers, and pull out the entire shaft (3) from the rear of the PTO. Remove all the pieces including the retaining shims.

LAIL11TL0711A0A

LAIL11TL0712A0A

11. Disassemble the lock ring (1) and bearing (2) from the PTO cover.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

12. Remove the snap retainer (1) on the PTO cover using a screwdriver.

LAIL11TL0713A0A

LAIL11TL0714A0A

LAIL11TL0715A0A

LAIL11TL0716A0A

13. Disassemble the lock ring (1) and cover (2).

14. Tighten the bolt (3) in the threaded piston orifice (2), remove the piston (2), and check the condition of the O-ring seal (1).

15. Disassemble the lubrication pressure relief valve (1) from the inner casing (2).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

16. Remove the accumulator cover (1).

LAIL11TL0717A0A

LAIL11TL0718A0A

LAIL11TL0719A0A

LAIL11TL0720A0A

17. Remove the accumulator parts, piston (1), spring (2) and cover (3).

18. Remove the clutch lock ring (1) and thrust ring (2), and then the clutch drive and driven discs.

19. Install the piston spring compressor 380000243 (1) on the clutch housing (2) as shown in the diagram. Tighten the nut to compress the spring.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

20. As soon as possible, remove the lock ring (1) using a screwdriver. Loosen the nut (2) and remove the tool 380000243 (3).

LAIL11TL0721A0A

LAIL11TL0722A0A

LAIL11TL0723A0A

LAIL11TL0724A0A

21. Using a compressed air gun, remove the piston (1) from the clutch housing (2).

22. Remove and inspect all the clutch assembly components. Check the condition of O-ring seals (1) and (2) and replace them if necessary.

23. Install the extractor with a separator (4) on the control shaft (2) and fasten the shaft in the vice. Place a support on the shaft (2) and extract the bearing.

Next operation: Three-speed rear Power Take-Off (PTO) - Assemble â&#x20AC;&#x201C; Electrohydraulic version (31.116).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Assemble â&#x20AC;&#x201C; Electrohydraulic version Prior operation: Three-speed rear Power Take-Off (PTO) - Disassemble â&#x20AC;&#x201C; Electrohydraulic version (31.116) .

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Check the condition of the components, particularly the clutch disc components. Replace all worn parts. 2. Install the piston (1) in the housing.

LAIL11TL0722A0A

LAIL11TL0721A0A

LAIL11TL0719A0A

3. Mount the spring and the spring retention device. Then install the tool 380000243 (2). 4. Tighten the tool nut (2) to compress the spring and install the lock (1). Once this is done, remove tool 380000243. 5. Heat the intermediate bearing. Mount the intermediate bearing to the gearbox transmission shaft. Install the clutch control cylinder.

6. Install the driven disks and the driver disks alternately in the clutch housing. Install the outer thrust ring. (2) Secure the outer thrust ring with the lock ring (1).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

7. Install the accumulator piston (1), the spring (2) and the cover (3). 8. Install the pressure relief valve.

LAIL11TL0718A0A

LAIL11TL0714A0A

LAIL11TL0713A0A

LAIL11TL0712A0A

9. Install the brake and secure the cover (2) with the lock ring (1).

10. Assemble the retainer (1) using a suitable tool to press the retainer into the base.

11. With the PTO cover in the vise, mount the rear bearing (2) and the lock ring (1).

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

12. Install the speed selection lever (2) on the cover. Secure the lever with a spring pin (1). 13. Assemble the spacer between the rear bearing and the 1000 RPM driven gear on the controlled shaft. 14. Install the 1000 RPM driven gear together with the sleeve, fork and bushing.

LAIL11TL0709A0A

LAIL11TL0704A0A

15. Partially assemble the speed selection rod (1) in order to hold the 540 - 1000 RPM gear selection sleeve in place. 16. Mount the 540 RPM gear and the thrust shim of the front bearing on the shaft.

17. Assemble the gear housing (2). 18. Install the camshaft (3) with the lock cylinder for the clutch disks (previously assembled).

LAIL11TL0711A0A

LAIL11TL0710A0A

19. Install the gear (4) and the lock rings (1) and (2) 20. Mount the spacer between the 750 RPM gear and the front bearing of the controlled shaft.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

21. Install the 750 RPM (1) driven gear.

LAIL11TL0706A0A

LAIL11TL0705A0A

LAIL11TL0702A0A

LAIL11TL0703A0A

22. Install the selection sleeve (1) and the fork (2).

23. Install the nut (2). NOTE: Torque the nut to 294.0 N·m (216.8 lb ft). 24. Lock the nut on the shaft.

25. Tighten the rod (3) of the fork (1) to the support (2) with the Allen bolt.

Next operation: Three-speed rear Power Take-Off (PTO) - Install – Electrohydraulic version (31.116) .

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Three-speed rear Power Take-Off (PTO) - Install â&#x20AC;&#x201C; Electrohydraulic version Prior operation: Three-speed rear Power Take-Off (PTO) - Assemble â&#x20AC;&#x201C; Electrohydraulic version (31.116) .

1. Clean the flush surfaces in the rear of the gearbox/ transmission box. 2. Assemble the two guide pins used previously during the removal of the PTO. 3. Clean the mating surfaces of the PTO. Apply a 2 mm layer of anaerobic sealant as shown in the figure to the side. 4. Fit the lifting hook to the PTO with a chain. 5. Place the PTO in front of the transmission box and use the winch to guide the PTO to the location pins. 6. Separate the lifting chain and fasten the PTO in the proper position with the four bolts.

LAIL11TL0699A0A

LAIL11TL0700A0A

LAIL11TL0701A0A

7. Remove the guide pins. 8. Fit the lock ring (1) onto the splined shaft. 9. Fit the drive plate for the splined clutch (2) and fit the lock ring (3) .

10. Clean the mating surfaces of the cover of the PTO (4) thoroughly. Apply 2 mm anaerobic sealant to the surfaces as shown in the figure to the side. 11. Fit the cover (4) and PTO protection. 12. Fit the PTO hydraulic pipes (lubrication, clutch, and clutch brake) to the connections on the PTO. 13. Mount the connection on the speed selection external lever. 14. Mount the control cable outer sleeve on the support.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

15. Raise the set using a lifting chain and a winch, then fasten it to the PTO using the six bolts. NOTE: Torque the screws to 221.0 NÂˇm (163.0 lb ft). 16. Fit the trailer hitch support and the third-point link arm. 17. Connect the negative battery cable.

LAIL11TL0693A0A

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Remove â&#x20AC;&#x201C; Electrohydraulic version WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Disconnect the negative (-) cable (1) from the battery.

CUIL13TRO0194AA

LAIL11TL0726A0A

LAIL11TL0727A0A

2. Remove the third point hitch bar (1).

3. Insert lifting chains through the towing hitch support (2). Unscrew the six bolts (1) and remove the support.

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

4. Separate the right-hand side lift arm (1) to facilitate access.

LAIL11TL0728A0A

LAIL11TL0729A0A

LAIL11TL0730A0A

LAIL11TL0731A0A

5. Remove the lock ring (1) securing the brake cover.

6. Remove the cover (1) using a screwdriver.

7. Insert the bolt (1) into the threaded orifice in the brake piston (2). Remove the piston using a pair of pliers.

Next operation: Power Take-Off (PTO) clutch brake - Install â&#x20AC;&#x201C; Electrohydraulic version (31.116) .

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Power Take-Off (PTO) - Three-speed rear Power Take-Off (PTO)

Power Take-Off (PTO) clutch brake - Install â&#x20AC;&#x201C; Electrohydraulic version CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Assemble the brake piston (2), the cover, and the lock ring.

LAIL11TL0731A0A

LAIL11TL0728A0A

2. Assemble the right-hand side lift arm (1). 3. Assemble the towing hitch. 4. Assemble the draw bar and the three-point link arm. 5. Connect the negative battery cable.

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Index Power Take-Off (PTO) - 31 Three-speed rear Power Take-Off (PTO) - 116 Power Take-Off (PTO) clutch brake - Install – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . . . .

Power Take-Off (PTO) clutch brake - Remove – Electrohydraulic version . . . . . . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Assemble – Electrohydraulic version . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Disassemble – Electrohydraulic version . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Install – Electrohydraulic version . . . . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Remove – Electrohydraulic version . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Sectional view – Electrohydraulic version . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Special tools – Electrohydraulic version . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-speed rear Power Take-Off (PTO) - Torque – Electrohydraulic version . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Brakes and controls TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015

Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.1

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Brakes and controls - 33 Hydraulic service brakes - 202

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Contents Brakes and controls - 33 Hydraulic service brakes - 202

SERVICE Hydraulic service brakes Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Brake master cylinder Brake master cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Hydraulic service brakes - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Disconnect the battery negative (-) cable (1). 2. Remove rear wheels. Consult the procedures in Rear wheels - Remove (44.520). 3. Remove the final drive housing. Consult the procedures in Final drive housing - Disassemble (27.120). NOTE: Do not remove the driven gear support from the final drive housing.

CUIL13TRO0194AA

LAIL11TL0010A0A

4. Loosen the connection (2) and remove the service brake control tube.

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5. Remove the crown (1), the spacer (3) and finally the brake disc (2) from the transmission box. 6. Remove the steel wear disc located between the transmission casing and the brake disc.

LAIL11TL0011A0A

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Hydraulic service brakes - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Hydraulic service brakes - Remove (33.202) . 1. Insert the wear disc (steel) in the transmission housing. 2. Install the brake disc (2), the spacer (3), and the ring gear (1).

LAIL11TL0011A0A

LAIL11TL0010A0A

3. Assemble the control tube (1) for the service brake. 4. Assemble the final drive housing. Consult the procedures in Final drive housing - Assemble (27.120). 5. Install the rear wheels.

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Hydraulic service brakes - Bleed The objective of the deaeration (bleeding) procedure is to remove air from the brake system. This procedure must be carried out in the following situations: • After the machine has been inactive for long periods. • After changing some parts of the braking system, such as the brake fluid or the master cylinder. • Lack of brake fluid. • Any other procedure that results in air getting into the braking system. 1. Place a suitably sized container under the component. 2. Carefully clean the external components close to the brake fluid reservoir cap. 3. Check that the brake fluid reservoir is topped up to the maximum level as indicated by the arrow before and during bleeding. NOTE: The brake fluid must not be reused. 4. Slowly press the right brake pedal fully down so that the fluid is under pressure. CUIL13TR00485AA

CUIL13TR00536AA

5. Keeping the pedal pressed down, loosen the bleed plug (1) a half turn and wait until fluid mixed with air flows through the bleed plug. 6. Loosen the bleed plug (1) and repeat the operations described above until the fluid flows with no air in it. 7. Press the brake pedal down again to put the circuit under pressure. When the pedal returns to the normal position, it will remain under pressure. 8. Repeat these operations for the braking circuit on the left-hand side. 9. When you have completed the procedure, top up the brake fluid in the reservoir. See the fluid specifications and the capacity of the system in Capacities ().

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Brake master cylinder - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Fit the cylinders, securing them with the bolts (2). Assemble the cylinders to the control pedals. 2. Connect the control tubes, reservoir and pressure sensor connections 3. Connect the negative battery cable. 4. Bleed the service brake. Consult the procedures in Hydraulic service brakes - Bleed (33.202).

LAIL11TL0014A0A

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Index Brakes and controls - 33 Hydraulic service brakes - 202

(*)

Brake master cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

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Contents Brakes and controls - 33

[33.202] Hydraulic service brakes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.2 [33.110] Parking brake or parking lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33.3

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CONSUMABLES INDEX Consumable Loctite® Loctite® Loctite® Loctite® Loctite®

515™ 515™ 515™ 515™ 515™

Reference Hydraulic service brakes - Sectional view Hydraulic service brakes - Sectional view Parking brake or parking lock - Sectional view Parking brake or parking lock - Service instruction Parking brake or parking lock - Install

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TECHNICAL DATA Hydraulic service brakes General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic service brakes Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Brake master cylinder - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Hydraulic service brakes Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Brake master cylinder Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

DIAGNOSTIC Hydraulic service brakes Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™

Reference Hydraulic service brakes - Sectional view Hydraulic service brakes - Sectional view

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Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Type Control system Service Brake Disc Material Disc thickness Maximum wear thickness Cylinders Operating pressure

TL60E TL75E TL85E TL95E Disks bathed in oil acting on the differential semi-shafts Hydrostatic, with independent pedals (connected by a pin) Sintered 9.600 mm (0.378 in) 0.1 mm With 2 master cylinders activated independently by brake pedals 17.6 bar (255 psi)

Hydraulic service brakes - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Torque value 176 NÂ·m (130 lb ft)

Reference (C1)

CUIL13TR00620AA

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Hydraulic service brakes - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Description and operation The service brakes are hydraulic with disks (organic or sintered) bathed in oil. Both control cylinders (master cylinder) - one for each pedal - are assembled on the front section of the cab and are linked to the respective pedals by two rods. These cylinders can be activated either independently or together. To be activated as a set, the pedals must be mechanically interconnected by a pin. A connecting tube between both cylinders guarantees balanced braking even when the brake disks are unevenly worn. The two master cylinders are supplied by a unique reservoir located above the cylinders. The brake disks (one for each rear wheel) are positioned between the rear transmission and the side end drive casing and are coupled with splines on the differential outlet semi-shafts.

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Hydraulic service brakes - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

CUIL13TR00621AA

Reference (1) (2) (3)

Component Brake wear plate Service brake valve Side end drive casing cylinder

Reference (4) (5) (6)

NOTE: During assembly, apply sealant LOCTITE® 515™ to the surfaces (X).

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Component Locating pin Piston of the brake control Sealants

Brakes and controls - Hydraulic service brakes

Hydraulic service brakes - Sectional view

CUIL13TR00622AA

Reference (1) (2) (3)

Component Brake wear plate Service brake valve Side end drive casing cylinder

Reference (4) (5) (6)

NOTE: During assembly, apply sealant LOCTITEÂŽ 515â&#x201E;˘ to the surfaces (X).

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Component Locating pin Piston of the brake control Sealants

Brakes and controls - Hydraulic service brakes

Brake master cylinder - Sectional view

LAIL11TL0948E0A

Reference (1) (2) (3)

Component Spring Cylinder body Control piston

Reference (4) (5) (6)

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Component Rear sealant Central sealant Front sealant

Brakes and controls - Hydraulic service brakes

Brake master cylinder - Dynamic description Brake master cylinders in the rest position With the pedals in the rest position, the bolt (2) moves the seal rings of piston (5), allowing the filling of the cylinder with brake oil. NOTE: For didactic issues, two colors have been used, but in this condition the oil in the cylinders is directly linked to the deposit. Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Output to the auxiliary cylinders Ring dislocation bolt Seals on the piston Brake oil input connection Main piston Cylinder body Pressure Oil Static oil Depot

CUIL13TR00634AA

CUIL13TR00635AA

Brake master cylinders with one pedal activated Activating one pedal moves the piston (5) away from the bolt (2). The sealants then touch the piston and start sending oil to the auxiliary brake cylinder. In the line that interconnects the two cylinders, the oil is pressurized, but does not act on the cylinder to the side, because the seals do not allow the passage of oil. NOTE: It is important that the cylinder drive rod has a clearance of 0.5 mm to maintain the piston in the sealing position (3). Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Output to the auxiliary cylinders Ring dislocation bolt Seals on the piston Brake oil input connection Main piston Cylinder body Pressure Oil Static oil Depot

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Master brake cylinders with both pedals activated Activating both pedals moves the piston (5) away from the bolt (2). The sealants then touch the piston and start sending oil to the auxiliary brake cylinder. The line that interconnects the two cylinders equalizes the pressure on both sides of the tractor to produce uniform braking. Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Output to the auxiliary cylinders Ring dislocation bolt Seals on the piston Brake oil input connection Main piston Cylinder body Pressure Oil Static oil Depot

CUIL13TR00633AA

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CUIL13TRO0194AA

LAIL11TL0010A0A

4. Loosen the connection (2) and remove the service brake control tube.

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5. Remove the crown (1), the spacer (3) and finally the brake disc (2) from the transmission box. 6. Remove the steel wear disc located between the transmission casing and the brake disc.

LAIL11TL0011A0A

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Prior operation: Hydraulic service brakes - Remove (33.202) . 1. Insert the wear disc (steel) in the transmission housing. 2. Install the brake disc (2), the spacer (3), and the ring gear (1).

LAIL11TL0011A0A

LAIL11TL0010A0A

3. Assemble the control tube (1) for the service brake. 4. Assemble the final drive housing. Consult the procedures in Final drive housing - Assemble (27.120). 5. Install the rear wheels.

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CUIL13TR00536AA

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LAIL11TL0014A0A

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Hydraulic service brakes - Troubleshooting Problem Possible Cause The brakes remain locked Master cylinder pistons blocked when the pedals are released Master cylinder jammed The pedal moves too Air in the brake circuit much Master cylinders worn Leaks from the control valves Difficulty activating the Corresponding master cylinder jammed brake pedals Brake control tubes blocked or bent Braking ineffective Wear to the friction material in the brake discs Master cylinders worn Air in the brake circuit Leaks from the control tubes Master cylinder seals worn or broken Uneven braking Wrong tire pressure Master cylinders worn Brake connection tube blocked or bent Brake control tubes blocked or bent Sealants in one of the control pistons worn or damaged Friction material in one of the brake discs worn The brakes are noisy Wear to the friction material in the brake disks.

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Correction Release the cylinder and replace the master cylinders if necessary Replace the master cylinders Bleed the cylinders Replace the cylinders Eliminate the causes of the leaks Replace the cylinder Clean or replace the control tubes Replace the brake discs Replace the master cylinders Bleed the air from the brake circuit Eliminate the causes of the leaks Replace the master cylinders Calibrate tire pressure Replace the brake control master cylinders Clean or replace the tube Clean or replace the control tubes Replace the master cylinders Replace the disc Replace the brake disks.

Index Brakes and controls - 33 Hydraulic service brakes - 202

(*)

Brake master cylinder - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake master cylinder - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake master cylinder - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic service brakes - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Brakes and controls - 33 Parking brake or parking lock - 110

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Contents Brakes and controls - 33 Parking brake or parking lock - 110

TECHNICAL DATA Parking brake or parking lock General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Parking brake or parking lock Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Parking brake or parking lock Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Hand brake lever Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 47835583 21/10/2015

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CONSUMABLES INDEX Consumable Loctite® 515™ Loctite® 515™ Loctite® 515™

Reference Parking brake or parking lock - Sectional view Parking brake or parking lock - Service instruction Parking brake or parking lock - Install

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - General specification Type Control system: Parking Brake Disc Material Parking brake mobile plates material Disc thickness Thickness of side plate on parking brake Intermediate thickness of parking brake plate

TL60E TL75E TL85E TL95E Disks bathed in oil acting on the pinion by means of a gear Mechanical, via a manual lever Steel Sintered or organic 3.95 - 4.05 mm 3.1 - 3.4 mm 4.2 - 4.5 mm

Parking brake or parking lock - Torque Reference (C2) (C3) (C4)

Component Fixing bolts for the drive shaft of the parking brake Guide bolts for the movable plates of the parking brake Bolts for fixing the parking brake in the rear transmission box

CUIL13TR00636AA

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Torque value 64 N·m (47.2 lb ft) 24 N·m (17.7 lb ft) 98 N·m (72 lb ft)

Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Dynamic description Park brake The parking brake is mechanically activated. It operates on the rear pinion shaft by means of an intermediate gear (on models with auxiliary front wheel drive, the intermediate gear is located in the transfer box). Control is through a lever located to the right of the operator. When the parking brake is activated the eccentric shaft acts on the mobile plates (pads) against the three machined brake disks on the intermediate gear shaft, this way stopping the tractor.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Sectional view

CUIL13TR00623AA

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

Component Driven Gear Driven gear pin Parking brake mobile plates Parking Brake Discs

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

NOTE: During assembly, apply sealant LOCTITEÂŽ 515â&#x201E;˘ to the surfaces (X).

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Component Internal parking brake control lever Parking brake support Locking ring Axial bearing housing

Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Service instruction TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

LAIL11TL0936B0A

Diagram to apply sealant ( LOCTITE® 515™) during assembly of the parking brake support in the transmission box.

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Remove WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Disconnect the battery negative (-) cable (1). 2. Lock the front wheels using shims. 3. Drain the rear transmission oil. Consult the procedures in Transmission housing - Drain fluid (21.114).

CUIL13TRO0194AA

LAIL11TL0019A0A

LAIL11TL0020A0A

4. Disconnect the control cable (2) and the return spring (3).

5. Loosen the retaining bolts and remove the parking brake support (1).

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Brakes and controls - Parking brake or parking lock

6. Loosen the fixing bolts (1) and remove the pin (2) together with the brake discs and the clutch.

LAIL11TL0021A0A

LAIL11TL0022A0A

LAIL11TL0023A0A

LAIL11TL0024A0A

7. Remove the plate support bolts (1) and remove the mobile plates.

8. Remove the fixing pin and remove the external parking brake control lever (1).

9. Loosen the retention bolt (1) and remove the internal parking brake lever.

Next operation: Parking brake or parking lock - Install (33.110) .

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Brakes and controls - Parking brake or parking lock

Parking brake or parking lock - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. Before assembling the parking brake support in the rear transmission box, thoroughly clean and remove any material from the mating surfaces and apply a thread of LOCTITEÂŽ 515â&#x201E;˘ sealant approximately 2 mm thick as shown in Parking brake or parking lock - Service instruction (33.110). 2. Assemble the internal lever (1) without the O-ring on the support, so that the ring seat can be seen in its entirety. Position the O-ring (2) in its seat and push the internal lever (1) to the operating position and fasten it to the bolt. 3. Assemble the external parking brake control lever. LAIL11TL0025A0A

4. Assemble the mobile plates and respective fixing bolts. 5. Assemble the pin complete with the brake disks and the clutch. 6. Position the brake support and fasten it to the transmission box. 7. Fill the rear transmission with oil. Consult the procedures in Transmission housing - Filling (21.114). 8. Connect the negative battery cable. Next operation: Hand brake lever - Adjust (33.110) .

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Brakes and controls - Parking brake or parking lock

Hand brake lever - Adjust Parking brake control lever travel must be adjusted whenever any work is done to the unit and when the drive lever is not on the third tooth with the brake engaged. Proceed as follows: 1. Loosen lock nut (1). 2. Tighten or loosen the adjustment bolt (2) until the control lever is locked on the third tooth. 3. Tighten the rod on the lock nut (1).

LAIL11TL0026A0A

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Index Brakes and controls - 33 Parking brake or parking lock - 110

(*)

Hand brake lever - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Service instruction (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Parking brake or parking lock - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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

47835583 21/10/2015 EN

SERVICE MANUAL Hydraulic systems TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Hydraulic systems - 35

[35.000] Hydraulic systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.1 [35.104] Fixed displacement pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.2 [35.322] Regulated/Low pressure system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.3 [35.204] Remote control valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.4 [35.114] Three-point hitch control valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35.5

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CONSUMABLES INDEX Consumable

Reference

NEW HOLLAND AMBRA GR Fixed displacement pump - Assemble 75 MD Three-point hitch control valve - Check NEW HOLLAND AMBRA MULTI G™ HYDRAULIC TRANSMISSION OIL Three-point hitch control valve - Install Loctite® 515™

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Hydraulic systems - 35 Hydraulic systems - 000

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Contents Hydraulic systems - 35 Hydraulic systems - 000

FUNCTIONAL DATA Hydraulic systems Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Schematic components Accurate diagrams of hydraulic circuits are essential to the technician who must repair them. The diagram shows how the components interact. The diagram shows how the system works, what each component should be doing and where the oil should be going so the technician can diagnose and repair the system. There are two types of circuit diagrams: • Cutaway circuit diagrams show the internal construction of the components as well as the flow paths. Using colors, shades or various patterns in the lines and passages, they show many different conditions of flow and pressure. Cutaway diagrams take considerably longer to produce because of their complexity. • Schematic circuit diagrams, the “shorthand” system of the industry, are usually preferred for troubleshooting. A schematic diagram is made up of simple geometric symbols for the components and their controls and connections. There are several systems of symbols used when making schematic diagrams: • ISO – International Standards Organization • ANSI – American National Standards Institute • ASA – American Standards Association • JIC – Joint Industry Conference A combination of symbols from these systems are shown. There are differences between the symbol systems. There is enough similarity, however, so if you understand the symbols shown, you will be able to interpret other symbols as well.

Reservoirs A rectangle with the top removed represents a vented reservoir (A). A rectangle with the top in place represents a pressurized reservoir (B).

RCIL07CCH025AAA

RCIL07CCH027AAA

RCIL07CCH030AAA

RCIL07CCH032AAA

There are other schematic diagrams that show a slightly different version of a pressurized reservoir, but the symbols are similar and easily recognized. An oval with a short line on top or a rectangle with curved sides represents a reservoir that is pressurized.

Lines connected to the reservoir usually are drawn from the top, regardless of where the actual connection is. This symbol shows a line which returns fluid above the level in the reservoir.

If the hydraulic line returns fluid below the level in the reservoir, it is drawn all the way to the bottom of the symbol.

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Hydraulic systems - Hydraulic systems

A hydraulic line connected to the bottom of the reservoir may be drawn from the bottom of the symbol if the bottom connection is essential to the systems operation.

RCIL07CCH033AAA

RCIL07CCH124AAA

RCIL07CCH034AAA

RCIL07CCH035AAA

RCIL07CCH036AAA

If the pump inlet (B) must be charged or flooded with fluid above the inlet port, the reservoir symbol (A) appears above the pump symbol, and the suction line is drawn out of the bottom of the reservoir symbol. Every system reservoir has at least two hydraulic lines connected to it, and some may have many more. Often the components that are connected to the reservoir are spread all over the schematic. Rather than multiplying lines all over the schematic, individual reservoir symbols are drawn close to the components. The reservoir is usually the only component symbol pictured more than once on a diagram.

Lines, tubes and hoses A hydraulic line, tube, hose or any conductor that carries the fluid between components is shown as a line. A working line, such as an inlet pressure or return, is shown as a solid line.

Working lines with arrows show direction of flow. In the first example (A), fluid flows in one direction only; in the second example (B), fluid can flow in both directions.

Pilot or control lines (A) are broken into long dashes. Drain lines (B) for leakage oil are broken into short dashes.

A flexible line is shown as an arc between two dots and is always represented by a solid line.

RCIL07CCH026AAA

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Hydraulic systems - Hydraulic systems

An enclosure outline indicates that there are several symbols that make up a component assembly such as a valve or a valve stack. The enclosure outline is rectangular and is broken with dashes on all sides.

RCIL07CCH028AAA

RCIL07CCH038AAA

RCIL07CCH047AAA

RCIL07CCH048AAA

RCIL07CCH040AAA

RCIL07CCH041AAA

Lines between components are drawn differently when they are crossing or connected. There are lines that cross other lines but are not connected. There are several ways to show crossing lines which are not connected.

Lines that are connected are shown with a dot that represents the connection or shown as a tee connection. The dot connection is the most commonly used when drawing schematic diagrams.

Pumps There are many basic pump designs. A simple fixed displacement pump (A) is shown as a circle with a solid arrow that pointing outward. The arrow points in the direction that the fluid flows. If the pump is reversible (B) or designed to pump in either direction, the symbol has two arrows which point in opposite directions. The pump normally has a pressure port and line (1) from which pressurized fluid is discharged and a suction port and line (2) into which fluid is drawn from the reservoir.

A variable displacement pump (A) is shown by an arrow drawn through the pump symbol at a 45 degree angle. A variable displacement, pressure compensated pump (B) is shown by a small box with an arrow, added to the side of the pump symbol.

If the pump is controlled by a lever (A) or a pedal (B), the appropriate symbol is added to the side of the pump.

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A drive shaft is shown as two short parallel lines extending from the side of the pump. A curved arrow, if present, on the drive shaft indicates the direction of rotation.

RCIL07CCH049AAA

RCIL07CCH051AAA

RCIL07CCH046AAA

RCIL07CCH055AAA

Motors Motor symbols are circles with solid black arrows, which point in the opposite direction of a pumpâ&#x20AC;&#x2122;s arrow, to show the motor as a receiver of fluid. One arrow is used for non-reversible motors (A); and two arrows are used for reversible motors (B).

A simple schematic diagram is shown of a hydraulic motor (A) connected to a hydraulic pump (B).

Cylinders A cylinder is a simple rectangle (A) representing the barrel. The piston and rod are represented by a tee (B), inserted into the rectangle. The symbol can be drawn in any position.

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If the cylinder is single-acting (A), there is only one port shown on the end of the cylinder that receives pressurized fluid. The opposite end of the cylinder is left open. Both ends are closed on a double-acting cylinder (B), and two ports are shown.

RCIL07CCH054AAA

RCIL07CCH057AAA

RCIL07CCH126AAA

RCIL07CCH080AAA

A double rod end cylinder has a rod extending from each end of the rectangle.

Some cylinders have cushions built into them. The cushion slows the movement of the piston as it nears the end of its stroke. Cylinder cushions are shown as a smaller rectangle (A) on the piston. If the cushion has an adjustable orifice, a slanted arrow is drawn at 45 degrees (B) across the symbol.

Accessories Filters, strainers and heat exchangers are represented as squares that are turned 45 degrees and have the port connections at the corners. A dotted line perpendicular to the flow line represent a filter, strainer or screen.

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A solid line perpendicular to the flow with solid arrows pointing outward represents a cooler.

RCIL07CCH081AAA

RCIL07CCH118AAA

RCIL07CCH119AAA

RCIL07CCH130AAA

The symbol for a heater is like the symbol for a cooler, except the solid arrows point inward.

Two sets of arrows pointing inward and outward represents a temperature control unit The solid arrows point in the direction that heat is dissipated. Or in the case of the control unit, they show that heat can be regulated.

An oval with details inside represents an accumulator. The details explain what type of accumulator it is: spring loaded (A), gas charged (B), or other features. The divider line indicates there is a separator between the charge and the fluid. A hollow arrow indicates gas. A spring indicates that the accumulator is spring-loaded.

Reference:

Hydraulic systems - Hydraulic symbol - Pressure control (35.000) Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Pressure control The basic valve symbol is a square (which is called an envelope) with external port connections and an arrow inside to show the fluid passage and direction of flow. The valve usually operates by balancing fluid pressure against a spring, so a spring is shown on one side of the symbol and a pilot pressure line on the other side.

Normally closed valve A normally closed valve, such as a relief or sequence valve, is shown with an arrow offset from the ports [inlet (A), outlet (B)] toward the pilot pressure line (C) side of the square. The spring (D) holds the valve closed until the pilot line pressure is greater than the spring pressure. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid can now flow through the valve. RCIL07CCH059AAA

RCIL07CCH060AAA

RCIL07CCH061AAA

Normally open valve A normally open valve is shown with the arrow connecting the inlet and outlet ports. It closes when pressure overcomes spring force. Mentally visualize a build up of pressure in the pilot line and the envelope moving over, compressing the spring. Fluid flow through the valve is now blocked.

Relief valve A relief valve is shown as a normally closed symbol connected between the pressure line (A) and the reservoir (B). The flow direction arrow points away from the pressure line port and toward the reservoir. This graphically represents how a relief valve operates. When pressure in the system overcomes the valve spring (C), flow is from the pressure line through the relief valve to the reservoir.

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Pressure reducing valve A pressure reducing valve is shown as a normally open symbol in a pressure line. This valve works opposite of a relief valve, since it senses outlet pressure (A) versus inlet pressure (B). As the outlet pressure builds, it works against a predetermined spring force. As the spring force is overcome, flow through the valve is reduced or shut off.

RCIL07CCH063AAA

RCIL07CCH062AAA

Sequence valve The normally closed symbol is also used for a sequence valve (A). The inlet port is connected to a primary cylinder (B) and the outlet port to the secondary cylinder line (C). When the piston in the primary cylinder reaches the end of its stroke, the pressure in the supply line increases. The sequence valve is also connected to the supply line and also feels the increase in pressure. As pressure increases, the envelope and directional flow arrow move over, connecting the inlet and outlet ports allowing fluid to flow to the secondary cylinder.

Reference:

Hydraulic systems - Hydraulic symbol - Directional control (35.000) Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Directional control One way valve A simple ball check valve is shown. When fluid pressure is exerted on the left side of the ball, the ball is forced into the “V” and no fluid can flow though the valve. When fluid pressure is applied to the right side of the ball, the ball moves away from the “V” and fluid can flow through the valve.

RCIL07CCH066AAA

RCIL07CCH067AAA

Bypass valve A bypass valve is shown as a one-way valve with a spring on the ball end of the symbol. Pressurized flow is necessary to overcome the spring force and allow flow around the ball.

Reference:

Hydraulic systems - Hydraulic symbol - Composite (35.000) Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Composite One way valve A more complex one-way valve is shown. This directional control symbol uses multiple envelopes with a separate envelope for each valve position. Within each envelope, arrows show the flow paths when the valve is shifted to that position. NOTE: All port connections are made to the envelope which shows the neutral condition of the valve. The left symbol (A) a one-way valve in the closed position. Mentally visualize a build up of pressure on the right side of the valve symbol (B) to enable free flow through the valve. RCIL07CCH072AAA

RCIL07CCH073AAA

RCIL07CCH074AAA

Two position valve Two envelopes (representing the spool) indicate a two position valve. Each envelopes shows the flow conditions for its position. This simple schematic shows fluid supplied to the rod end of the cylinder (A) from the control valve (B). Return flow is from the piston end of the cylinder through the control valve to tank.

Mentally visualize the directional control valve shifted to the other position. Pressurized fluid is supplied to the piston end of the cylinder (A) from the control valve (B), and return fluid flows from the rod end of the cylinder through the control valve to tank.

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Hydraulic systems - Hydraulic systems

Three position valve Three position valves have a centered (neutral) position. The centered position can be either open or closed to flow. The open center (A) is usually used with a fixed displacement pump, while the closed center (B) is usually used with a variable displacement pump.

RCIL07CCH068AAA

RCIL07CCH069AAA

RCIL07CCH017BAA

Actuating controls Valve spools are controlled by pedals (A), levers (B), pilot fluid (C), electric solenoids (D), etc., which are called actuating controls. These actuating controls are shown by symbols placed on the ends of the envelopes. This symbol (E) is used when a solenoid is controlled with internal pilot assist pressure.

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Hydraulic systems - Hydraulic systems

To show that a valve is spring-centered, a spring symbol is placed at each end of the envelope. This symbol shows that a solenoid and pilot pressure assist are required to overcome spring force to move the valve spool.

RCIL07CCH070AAA

Reference:

Hydraulic systems - Hydraulic symbol - Flow control (35.000) Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Flow control Restrictors The basic flow control symbol is a restrictor. If the restrictor is adjustable, a slanted arrow is drawn across the symbol. The restrictor could be a special fitting with a small hole in it or a small drilled passageway within a valve. An adjustable restrictor acts like a faucet: adjusting the restriction regulates flow. Restrictors are used to meter and bleed circuits.

RCIL07CCH075AAA

RCIL07CCH078AAA

Adjustable restrictors can be pressure-compensated: the size of the opening in the restrictor changes with increases and decreases in pressure. A perpendicular arrow indicates pressure compensation. If the restrictor has both pressure and temperature compensation, the symbol for a thermometer is added.

Reference:

Hydraulic systems - Hydraulic symbol - Table of symbols (35.000)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic symbol - Table of symbols Line and line functions Solid line - main line

Dotted line - exhaust or drain line

Dashed line - pilot line

Enclosure outline

Lines crossing

Lines joining

Lines crossing

Liquid direction of flow

Gaseous direction of flow

Flexible line

Mechanical devices Connections (two parallel lines) for shafts, levers, etc.

Variable component (arrow intersects symbol at 45 Â°)

Spring

Pumps and motors Pump, fixed displacement

Pump, variable displacement

Pressure compensated, variable displacement pump

Fixed displacement pump (bidirectional flow)

Motor, fixed displacement

Motor, variable displacement

Oscillator

Reservoirs

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Hydraulic systems - Hydraulic systems

Reservoir, open to atmosphere

Pressurized reservoir

Return line to reservoir below fluid level

Return line to reservoir above fluid level

Cylinders Single acting

Double acting, single rod end

Double acting. double rod end

Single rod end, fixed cushion both ends

Single rod end, adjustable cushion, rod end only

Differential cylinder

Valves Check valve

Pilot-operated check valve

On/Off manual shut off valve

Regulating or selector valves

2 position, 2 way valve

2 position, 3 way valve

2 position, 4 way valve

3 position, 4 way valve

2 position, 4 way open center, crossover valve

Valve capable of infinite positioning (indicated by horizontal lines parallel to the envelope)

Pressure relief valve

Pressure reducing valve

Non-adjustable restrictor valve

Adjustable restrictor valve

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Hydraulic systems - Hydraulic systems

Adjustable restrictor, pressure compensated

Adjustable restrictor, temperature and pressure compensated

Valve actuators Solenoid

Detent

Spring

Manual

Push button

Lever

Pedal

Mechanical

Pressure compensated

Pilot pressure, remote supply

Liquid supply

Accessories Filter

Cooler

Heater

Temperature controller

Accumulator (hydropneumatic

Reversing motor

Station or test point

Pressure indicator

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Hydraulic systems - Hydraulic systems

Temperature indicator

Pressure switch

Quick disconnect (disconnected)

Quick disconnect (connected)

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Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema Tractor with Power Take-Off (PTO) and electrohydraulic differential lock

CUIL13TR00841AA

Reference (1)

Component Lift valve Pressure relief valve 210.0 - 215.0 bar (3045.0 - 3117.5 psi)

Reference (14)

(3)

Lift cylinder

(16)

(4)

Steering cylinder – Left-hand side

(17)

(5)

Steering cylinder – Right-hand side

(18)

(6)

Hydrostat or hydrostatic unit

(19)

(7) (8) (9) (10) (11)

Power Take-Off (PTO) clutch Accumulator PTO BRAKE Differential Lock Pressure switch Engagement of the auxiliary front wheel drive (AFWD) Lubrication of the bearings and of the PTO clutch disks

(20) (21) (22) (23) (24)

(2)

(12) (13)

(15)

(25)

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Component Lubrication valve Lubrication of the rear bearing of the PTO Lubrication relief valve – 5.0 - 8.0 bar (72.5 - 116.0 psi) Pressure relief valve - 16.0 - 17.0 bar (232.0 - 246.5 psi) Differential lock valve, PTO and PTO power drive Check valve 165.0 - 170.0 bar (2392.5 - 2465.0 psi) Steering Pump – 14 cm³/rev Filter Oil tank Lift pump – 19 cm³/rev Motor power drive Pressure relief valve - 190.0 bar (2755.0 psi)

Hydraulic systems - Hydraulic systems

Hydraulic systems - Hydraulic schema

CUIL13TR00837AA

Reference (1) (2)

Reference (9) (10)

Component Filter Oil tank

(11)

Steering cylinder – Left-hand side

(12)

Steering cylinder – Right-hand side

(5)

Component Lift valve Lift cylinder 210.0 - 215.0 bar (3045.0 - 3117.5 psi) Pressure relief valve Pressure relief valve 190.0 bar (2755.0 psi) Motor power drive

(13)

(6)

Pump

(14)

(7)

Steering Pump – 14 cm³/rev

(15)

(8)

Pump – 19 cm³/rev

(16)

Hydrostat or hydrostatic unit 165.0 - 170.0 bar (2392.5 - 2465.0 psi) Check valve Drive valve of the auxiliary front wheel drive Pressure switch

(3) (4)

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Index Hydraulic systems - 35 Hydraulic systems - 000 Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Composite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Directional control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Flow control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Pressure control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Schematic components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic systems - Hydraulic symbol - Table of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Fixed displacement pump - 104

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Contents Hydraulic systems - 35 Fixed displacement pump - 104

TECHNICAL DATA Fixed displacement pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Fixed displacement pump Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Fixed displacement pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

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CONSUMABLES INDEX Consumable

Reference

NEW HOLLAND AMBRA GR Fixed displacement pump - Assemble 75 MD

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - General specification Type Location Model Manufacturer Drive system Rotation direction (from the side of the operator) Engine rpm and pump rpm ratio Maximum nominal flow rate - Engine at 2600 RPM Maximum actual flow rate - Engine at 2600 RPM Maximum rpm (engine at maximum power) Maximum System Pressure Type of filter Location Work test flow*, at 1450 RPM and pressure of 153 bar (2218.5 psi): - New or recovered pump Work test flow*, at 1450 RPM and pressure of 153 bar (2218.5 psi) - Used pump Drive and driven gear shaft diameter Internal diameter of the seats in the supports Gap between the gear shafts and the seats Maximum clearance between the gear shaft and the seats due to wear Radial gap of gears within the pump housing Maximum wear within the pump housing on the suction side where the gears are located Gear lengths Length of the bearing housings Length of pump body Axial play of the complete gears with supports on the pump housing (recovered if required)

TL60E TL75E TL85E TL95E With gears drawing oil from the transmission box Behind the distribution gear cover C42 NEW HOLLAND Activated by an engine distribution mechanism To the right 1:0,931 46,45 l/min 39,5 l/min 2328 RPM 190 bar Paper cartridge Installed on the pump body on the suction side 25.8 l/min 18 l/min 17.400 - 17.418 mm 17.450 - 17.470 mm 0.032 - 0.075 mm 0.1 mm 0.020 - 0.064 mm 0.1 mm 30.800 - 30.815 mm 24.490 - 24.510 mm 79.935 - 79.960 mm 0.100 - 0.180 mm

(*). Temperature of the test oil: 55 - 65 Â°C. Oil used: SAE 20W

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Exploded view

CUIL13TR00697AA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Screw Lock washer Rear cover Seals Pump body Gear bushing Bearing housings

Reference (8) (9) (10) (11) (12) (13)

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Component Driven Gear Bearing housings Seals Front cap Retainer Lock ring

Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Exploded view

CUIL13TR00699AA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Fixing bolt Rear cover Bushing Seals Journal Pump body Drive gear Driven Gear

Reference (9) (10) (11) (12) (13) (14) (15) (16)

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Component Journal Journal Retainer Seals Ring Lock ring Nut Front cap

Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Remove 1. Remove the coupling (1) for the pressure tube of the lift pump.

CUIL13TR00694AA

CUIL13TR00693AA

CUIL13TR00695AA

CUIL13TR00696AA

2. Remove the clamps (2) and (3) and the hose (1) of the filter inlet hose. 3. Remove the bolts (5) and remove the pressure tube (4). 4. Remove the bolts (7) and remove the support along with the tube (8). 5. Remove the filter (10). NOTE: Dispose of the fluid properly. Adhere to the legislation in effect in your region or country.

6. Remove the bolts (2) for fixing the filter support (1) to the plate (4). 7. Remove the bolts (3) for fixing the plate (4) to the lift pump.

8. Remove the four fixing bolts (1) of the lift pump.

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Disassemble 1. Remove the fixing bolts (1) from the rear cover (2). 2. Remove the sleeve fixing nut (14) on the pump and driven shaft as well as its respective lock. (15) 3. Remove the front cover (16), the lock ring (14), and the retainer (11). 4. Identify the parts (5), (6), (7), (8), (9), and (10) in order to re-assemble them in the same position, provided they are in good condition. 5. Remove the bearings (5), (9) and (10), and the gears (7) from the front cover (16) and from the pump housing (6). 6. Remove the sealants (4) and (12) and the anti-extrusion rings.

CUIL13TR00699AA

Next operation: Fixed displacement pump - Inspect (35.104) .

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Inspect Prior operation: Fixed displacement pump - Disassemble (35.104) . 1. Check that the gear contact surfaces are flat and perpendicular to the supports. Insert a thin carbon paper sheet. The small rough spots can be removed by using an adequately lubricated very fine abrasive sandpaper. 2. Check that the axial clearance of the gear support on the pump housing is between 0.100 - 0.180 mm. The distance (2) must be 0.100 - 0.180 mm less than the distance (1). 3. Clean all of the parts thoroughly.

LAIL11TL0835A0A

CUIL13TR00699AA

4. Replace the seals (4), (11) and (12). 5. Lubricate the parts with hydraulic oil.

Next operation: Fixed displacement pump - Assemble (35.104) .

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Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Assemble Prior operation: Fixed displacement pump - Inspect (35.104) . NOTICE: Always ensure maximum cleanliness to avoid foreign materials from entering the pump as this may result in damage. 1. Install the parts identified previously (5), (6), (7), (8), (9), and (19). 2. Install the gear bearings (7) and (8) within the pump housing. 3. Install the anti-extrusion plastic rings within the seals. 4. Assemble the retainer (11) on the front cover (16). 5. Fill the chamber with NEW HOLLAND AMBRA GR 75 MD grease. 6. Install the rear cover (2). Secure the cover with the bolts (1). Apply a torque of 44.0 - 50.0 NÂˇm (32.5 36.9 lb ft) . Next operation: Fixed displacement pump - Install (35.104) .

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LAIL11TL0996F0A

Hydraulic systems - Fixed displacement pump

Fixed displacement pump - Install Prior operation: Fixed displacement pump - Assemble (35.104). 1. Install the pump. Secure the pump with the bolts (1). Torque to 8.9 - 11.6 N·m.

CUIL13TR00696AA

CUIL13TR00695AA

CUIL13TR00693AA

CUIL13TR00694AA

2. Install the plate (5). Secure the plate with the bolts (3). Torque to 22 - 29 N·m. NOTE: Install new seal rings (4) and (6). 3. Install the filter support (1). Secure the support with the bolts (2). Torque to 22 - 29 N·m.

4. Fill the filter with the specified oil. Install filter (10). 5. Install the tube (8). Secure the tube with the bolts (7). Torque to 8 - 12 N·m. 6. Install the pressure tube (4). Secure the pressure tube with the bolts (5). 7. Install the hose (1) and install the clamps (2) and (3).

8. Install the coupling (1) for the pressure tube of the lift pump. Torque to 85 - 105 N·m.

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Index Hydraulic systems - 35 Fixed displacement pump - 104 Fixed displacement pump - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Fixed displacement pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Hydraulic systems - 35 Regulated/Low pressure system - 322

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Contents Hydraulic systems - 35 Regulated/Low pressure system - 322

TECHNICAL DATA Low pressure valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Low pressure valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Regulated/Low pressure system Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Low pressure valve Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

SERVICE Regulated/Low pressure system Regulated/Low pressure system - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Low pressure valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

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Hydraulic systems - Regulated/Low pressure system

Low pressure valve - General specification TL75E Clearance between the rod (11)* and the housing Clearance between the pressure relief valve (20)* and the housing Pressure relief valve spring (18)* (with free length) Pressure relief valve spring (18)* (length under a load of 29.17 kg + 1.30 kg) Relief valve pressure adjustment (20)*

TL85E

TL95E

0.025 - 0.035 mm 0.025 mm 127 mm 102.5 mm 16.0 - 17.0 bar (232.0 - 246.5 psi)

(*). Refer to the references in Low pressure valve - Sectional view (35.322).

Low pressure valve - Special tools NOTICE: The operations described in this section must only be performed using the essential tools that appear below with the symbol (X). However, for greater safety and to obtain the best results as well as saving time and effort, it is recommended that these essential tools be used together with the specific tools listed below and certain tools that should be made according to the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section: X

380000552

Pressure Gauge 0.0 - 40.0 bar (0.0 - 580.0 psi)

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Hydraulic systems - Regulated/Low pressure system

Regulated/Low pressure system - Hydraulic schema

CUIL13TR00838AA

1 2. 3. 4. 5. 6. 7. 8. 9.

Pressure line between the pump and the hydrostatic steering unit. Hydrostatic steering anti-cavitation tank. Hydrostatic steering lines. PTO clutch brake cylinder line. PTO clutch engagement line. Lubrication line for the PTO clutch bearing. Rear differential lock coupling line. Transmission oil suction line. Front wheel drive engagement line.

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

Control valve (PTO clutch and clutch brake, rear differential lock, front wheel drive). Feed line from the hydrostatic steering anti-cavitation tank (2). (2) Oil filter. Hydraulic pump. Lubrication oil Static oil Oil inlet suction Oil under pressure

The pump (14) draws the oil from the rear transmission box through the suction line (8). (14) (8) The oil is fed through the filter (13) and on through the line (3) to the steering sector (orbitrol). (13) (3) Once it has passed through the steering sector, the excess oil is sent to the anti-cavitation reservoir (2) and from there it travels along the tube (11) to the control valve (10). The control valve (10) enables: • Control of the cylinder of the Power Take-Off (PTO) clutch brake, through the line (4). • Control of the PTO clutch engagement cylinder through line (5). (5) • Lubrication of the bearings and the PTO clutch. • Control of the rear differential lock through line (7). (7)

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Hydraulic systems - Regulated/Low pressure system

Low pressure valve - Sectional view Sections of the control valve of the hydraulic operation with solenoids

LAIL11TL1098F0A

Reference (a) (1) (2) (3) (4)

(5)

(6) (7) (8) (9) (10)

Component Component Reference Lever position for synchronised PTO Lever position for direct drive PTO (driven (b) (driven from the gearbox). from flywheel). Rod that controls the oil pressure for the Solenoid that controls the disengagement (11) solenoid (14) of the front wheel drive Control solenoid for the rear differential (12) Fixing bolt for valve (11) lock (13) Seal and dust cover for valve (11) Pressure line for the rear differential lock Pressure sensor on the front drive control Solenoid that controls the oil pressure for the (14) line PTO clutch and for the clutch brake Lever that restricts the oil pressure to the solenoid (14) and that controls the Transportation line connection for the clutch engagement of the direct-drive PTO (15) brake clutch, when the synchronized PTO is engaged Pressure line connection for PTO clutch Tappet for valve travel adjustment (11) (16) engagement cylinder Pressure line connection for front drive (17) Return line to transmission box engagement Pressure line connection for PTO rear (18) Spring for pressure relief valve bearing lubrication Connection for connecting the pressure (19) Pressure line fitting for the solenoid block relief valve to the return line Outer plug on the return line (20) Pressure relief valve

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Hydraulic systems - Regulated/Low pressure system

Regulated/Low pressure system - Pressure test CAUTION Escaping fluid! Hydraulic fluid or diesel fuel leaking under pressure can penetrate the skin and cause infection or other injury. To prevent personal injury: Relieve all pressure before disconnecting fluid lines or performing work on the hydraulic system. Before applying pressure, make sure all connections are tight and all components are in good condition. Never use your hand to check for suspected leaks under pressure. Use a piece of cardboard or wood for this purpose. If injured by leaking fluid, see your doctor immediately. Failure to comply could result in minor or moderate injury. C0104A

Before performing hydraulic adjustments and tests: • Analyse and understand the hydraulic flow of the different functions and circuits. • Make sure that the oil level is correct. • Make sure of the correct specification of oil used. • Make sure of the good condition of the system's oil filter. If necessary, replace the filter. NOTE: All tests and adjustments must be conducted with an oil temperature of at least 50.0 °C (122.0 °F).

Testing the pressure regulating valve 1. Park the machine on a level and hard surface. 2. Install a "T" connection between the tube (1) and the port (2). 3. Install the pressure gauge 380000552 with a pressure scale between 0.0 - 40.0 bar (0.0 - 580.0 psi) on the "T" connection. 4. Start the engine. 1500 RPM.

Adjust the engine speed to

CUIL13TR00774AA

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Hydraulic systems - Regulated/Low pressure system

5. Make sure that the selector valve (1) is closed (positioned downward).

CUIL13TR00802AA

CUIL13TR00774AA

CUIL13TR00794AA

CUIL13TR00802AA

6. Make sure that the electrohydraulic differential lock is disengaged. The solenoid (1) will be de-energized. 7. Make sure that the Auxiliary Front Wheel Drive (FWD) is engaged. The solenoid (2) will be de-energized. 8. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi).

9. If the pressure is incorrect, adjust the assembly of the pressure regulating valve (1) and (2) or replace the valve. 10. If the pressure is correct, proceed with the leak tests indicated below.

Leak test on the coupling mechanism of the Auxiliary Front Wheel Drive (FWD) With the pressure gauge still installed, perform the following procedures: 1. Make sure that the selector valve (1) is closed (positioned downwards).

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2. Make sure that the electrohydraulic differential lock is disengaged. The solenoid (1) will be de-energized. 3. Make sure that the Auxiliary Front Wheel Drive (FWD) is disengaged. The solenoid (2) will be energized. 4. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi). 5. If the pressure is incorrect, service the drive system of the Auxiliary Front Wheel Drive (FWD). Check for likely pressure leaks through the seals or for wear on the coupling sleeve inside the transfer box. Consult the procedures in Four-Wheel Drive (4WD) gearbox Remove (23.304).

CUIL13TR00774AA

CUIL13TR00802AA

6. If the pressure is correct, perform the leak test described below.

Leak test on the differential lock system With the pressure gauge still installed, perform the following procedures: 1. Make sure that the selector valve (1) is closed (positioned downwards). 2. Make sure that the electrohydraulic differential lock is engaged. The solenoid (1) will be energized. 3. Make sure that the Auxiliary Front Wheel Drive (FWD) is engaged. The solenoid (2) will be de-energized. 4. The pressure indicated on the pressure gauge should be 16.0 - 17.0 bar (232.0 - 246.5 psi). 5. If the pressure is incorrect, service the mechanisms of the differential lock, seeking to eliminate likely pressure leaks through the piston seals. 6. If the pressure is correct, this means that there is no issue with the hydraulic circuit examined in the recent tests. Perform the tests on the hydraulic circuit of the Power Take-Off (PTO) by following the procedures described in Power Take-Off (PTO) clutch oil supply line - Pressure test (31.104).

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Low pressure valve - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

To remove the control valve, proceed as follows: 1. Disconnect the negative (-) cable (1) from the battery. 2. Drain the fuel from the fuel tank. Consult the procedures in Fuel tank - Drain fluid (10.216). 3. Put shims on the tractor's front wheels. 4. Remove the rear left wheel.

CUIL13TRO0194AA

LAIL11TL1091A0A

LAIL11TL0737A0A

5. Disassemble the clamp (1) and separate the injection pump feed pipe (2). 6. Remove the fuel tank. Consult the procedures in Fuel tank - Remove (10.216).

7. Disconnect the tube (4) from the solenoid block. 8. Remove the fixing bolt for the tappet to adjust the valve cursor (2) for the rod (1). 9. Remove the control lever (3). NOTE: The control rod (1), via the hydraulic system, prevents the engagement of the direct-drive Power Take-Off (PTO) clutch when the synchronized PTO is engaged.

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10. Remove the bolts (1) that secure the control valve to the gearbox. Remove the control valve.

LAIL11TL0738A0A

Next operation: Low pressure valve - Disassemble (35.322).

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Low pressure valve - Disassemble Prior operation: Low pressure valve - Remove (35.322). Proceed as follows: 1. Remove the lock ring (6), washer (4) and pin (5). 2. Loosen the end of travel bolt (1) and disassemble the rod (3). 3. Disassemble the O-ring lining seal and dust cover ring (2).

LAIL11TL0740A0A

LAIL11TL0741A0A

LAIL11TL0742A0A

4. Remove the plug (1) on the return line for the transmission to check the seal's condition (2). NOTE: Also check the condition of the seals (3) and (5) located in the outlet (4) in the return line to the transmission box.

5. Disassemble the rear differential lock connection (3). 6. Disassemble the supply line connection (1) to the solenoid block (2). 7. Disassemble the connection (4) which connects the pressure relief valve to the return line. 8. Disassemble the spring (5) and pressure relief valve (6).

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9. Place the control valve block in the vice. 10. Disassemble the nuts (2) and the solenoid coils (1). NOTE: Mark the components to facilitate assembly.

LAIL11TL0743A0A

LAIL11TL0744A0A

LAIL11TL0745A0A

11. Disassemble the three solenoid valves (1). 12. Check the condition of the seals and replace them if necessary.

13. Remove the pressure sensor (1). Check its operation.

Next operation: Low pressure valve - Assemble (35.322).

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Low pressure valve - Assemble Prior operation: Low pressure valve - Disassemble (35.322). 1. Check the condition of all the seals and replace those that are defective. 2. Carefully inspect and clean all the mechanical parts. 3. Install the pressure sensor (1).

LAIL11TL0745A0A

LAIL11TL0744A0A

LAIL11TL0743A0A

4. Install the three solenoid valves by tightening the nuts (1) to a torque of 48 - 55 NÂˇm (35 - 41 lb ft).

5. Install the coils (1) tightening the nuts (2) to a torque of 5.5 - 8.3 NÂˇm (4.1 - 6.1 lb ft)).

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6. Install the cover (1). 7. Install the pressure relief valve parts by following the disassembly procedure in the reverse order.

LAIL11TL0741A0A

LAIL11TL0746A0A

8. Install the seal ring for the dust cover (2). 9. Assemble the valve (3) on the casing and fit bolt (1). 10. Assemble the control lever on the articulated pin (5), mount the washer (4) and lock ring (6). 11. Mount the supply line fitting to the rear differential lock.

Next operation: Low pressure valve - Install (35.322).

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Low pressure valve - Install Prior operation: Low pressure valve - Assemble (35.322). 1. Mount the control valve on the gearbox using the bolts (1).

LAIL11TL0738A0A

LAIL11TL0739A0A

LAIL11TL1091A0A

2. Assemble the control lever (2) to the rod (1). 3. Adjust the rod lever via the tappet adjustment nut to create play between the rod (1) and the limiting bolt (3) in the end-of-travel positions. A. Position of the synchronized Power Take-Off (PTO). B. Position for the direct drive PTO with electric hydraulic control. 4. Assemble the supply and return lines on the control valve. 5. Install the fuel tank. Consult the procedures in Fuel tank - Install (10.216). 6. Assemble the feed tube (2) for the injection pump. 7. Install the rear left wheel. 8. Connect the negative battery cable.

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Index Hydraulic systems - 35 Regulated/Low pressure system - 322 Low pressure valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Low pressure valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulated/Low pressure system - Pressure test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Regulated/Low pressure system - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Contents Hydraulic systems - 35 Remote control valves - 204

TECHNICAL DATA Remote control valves General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Remote control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

SERVICE Remote control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disassemble â&#x20AC;&#x201C; Double-acting cylinder with detent and float control (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

(*) See content for specific models 47835583 21/10/2015

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Remote control valves - General specification Filter Pump Location of the remote control valve Drive system Regulating pressure of the relief valve Type

TL60E TL75E TL85E TL95E Full flow filter with paper cartridge (common for hydraulic lift circuits) Gear pump Valve body (up to a maximum of 2 valves) installed on the gear control rods housing cover Through the activation rod 190 bar Open center system, convertible for operation with single-acting or double-acting actuators, and with automatic disarm, for operation of double-acting actuators with float control and automatic disarm

Remote control valves - Torque Torques Remote control valve fixing bolts

Torque value 59.0 NÂˇm (43.5 lb ft)

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Remote control valve - Exploded view

CUIL13TR00701AA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Rod link Nut Valve body Valve seal Sealing rings Valve

Reference (8) (9) (10) (11) (12) (13) (14)

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Component seal Seal seal Relief valve Body Valve tie rod Nut

Hydraulic systems - Remote control valves

Remote control valve - Exploded view

CUIL13TR00703AA

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

Component Valve Plug seal Sealing rings Detent mechanism

Reference (6) (7) (8) (9)

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Component Screw Retainer seal Commutator valve

Hydraulic systems - Remote control valves

Remote control valve - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Configuration for operation of the double-acting cylinder

CUIL13TR00643AA

Reference (1)

Component Cap

Reference (6)

(2)

Separator

(7)

(3) (4) (5)

Rod check valve Retention valve seat

(8) (9) (10)

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Component Sealant Dual to simple action operation shift valve Sealant Plug Sealant

Hydraulic systems - Remote control valves

Configuration for operation of the single-acting cylinder

CUIL13TR00644AA

Reference (11) (12) (13)

Component Rod return spring Dish Sealant

Reference (14) (15) (16)

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Component Sealant Sealant Control lever support

Hydraulic systems - Remote control valves

Configuration for the operation of the double-acting cylinder with float control and automatic disarm

CUIL13TR00645AA

Reference (17) (18) (19) (20) (21) (22) (23) (24)

Component Conical needle Sealant Spring Detainer bearings Detainer bearings support Sealant Inner piston Spring

Reference (25) (26) (27) (28) (29) (30) (31)

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Component Cap Detainer pressure adjustment bolt Rod return spring Dish Sealant Sealant Bearing housing

Hydraulic systems - Remote control valves

Remote control valve - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

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Remote control valve operational phase to engage the dual action cylinder with rod detent and floating position Neutral

CUIL15TR00116GA

(1). Static oil (2). Oil being discharged (3). Pressure Oil When the control rod (4) is in the central position, the galleries (6) and (8) are not linked to the galleries (5), (7) and (9), such that the oil becomes static. In this situation, the full flow of oil from the hydraulic pump runs through gallery (10) to the other parts of the remote control (open center system) and, where unused, follows on to feed the hydraulic lift control valve.

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Operation of remote control in floating position

CUIL15TR00148GA

(1). Pressure Oil (2). Oil being discharged To select the operating float control, activate the control lever (located in the cab) fully forward. The valve control rod (3) moves and the tab of the balls (8) and (9) engages in the notch on the right where they are kept in position by the support and by the spring (10). In that position the rod (3) links the gallery (11) that carries the full pump flow to the other sections of the remote control. The galleries (5) and (6) are linked to the galleries (4) and (7). In that condition, the only force acting on the coupled implement is that created by its weight and hydraulic lift may be activated. The automatic disarm does not operate with the float control because there is no pressure inside the remote control valve.

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Hydraulic systems - Remote control valves

Phases of operation of the remote control valve driving a double-acting cylinder and with automatic disarm Raise

CUIL15TR00118GA

(7). Pressure Oil (8). Oil being discharged (9). Static oil When the control lever (located in the cab) is pulled back, the rod (2) moves and the ball tab (26) engages with the fitting on the left, where it is secured by the support (28) and spring (24). The movement of the rod (2) connects: the feed gallery (E) to the lower cylinder chamber through the check valve (3) and the gallery (G), as well as the upper cylinder chamber to the return line (L) through the gallery (H), which intercepts the oil supply to the control valve for the hydraulic lift. On completion of the lifting movement, the oil pressure rises to 170 - 175 bar (2465 - 2538 psi). Acting through the gallery (Y), the spring overcomes the resistance of the needle valve (23). Inside chamber (T), the oil pressure increases and, acting on the ball tab support (26), overcomes the resistance of the spring thus moving the 47835583 21/10/2015

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support (28). The two ball tabs (26) therefore drop onto the support and release the rod (2) which, under the influence of the spring (6), returns to the neutral position. The full pump flow is then driven to the lift control valve through lines (M).

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Lower

CUIL15TR00119GA

(4). Pressure Oil (5). Oil being discharged (6). Static oil To lower the implement, activate the control lever forward (in the cab). The valve control rod (2) moves and the ball tab engages with the central groove where it is kept in position by the support (28) and spring (24). The oil contained in the lower chamber of the cylinder can therefore flow to the return (L) through gallery (G), while the top chamber connects to the feed (E) through gallery (H) and the retention valve (3). When lowering is completed, the tab is automatically released as previously described.

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Phases of operation of the remote control valve for operating the double-acting cylinders Neutral

CUIL15TR00120GA

(1). Static oil (2). Oil being discharged (3). Pressure Oil When the control rod (9) is in the central position, the galleries (5) and (7) are not linked to the galleries (4), (6) and (8), such that the oil becomes static. In this situation, the full flow of oil from the hydraulic pump runs through gallery M to the other parts of the remote control (open center system) and, where unused, follows on to feed the hydraulic lift control valve. (10)

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Raise

CUIL15TR00121GA

(1). Static oil (2). Oil being discharged (3). Pressure Oil By pulling the command lever back, the valve control rod (11) moves to connect: the feed gallery (8) to the lower cylinder chamber through the retention valve (7) and the gallery (9) as well as the return gallery (5)through the gallery (6), which intercepts the supply of oil from the lift control valve. Maintain the rod pulled back to extend the cylinder to its full cycle. When released, the lever automatically returns to the neutral position under the action of the return spring and the full pump flow is directed to the main hydraulics lift control valve through lines (M). (12)

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Lower

CUIL15TR00122GA

(1). Static oil (2). Oil being discharged (3). Pressure Oil To lower the implement, engage the control lever forward. The control valve rod (10) moves to the position indicated in the figure 2 so that the oil in the lower cylinder chamber flows to the return (9) through the gallery (8), while the upper chamber remains connected to the pressure gallery (7) through the gallery (5) and the check valve (6).

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Hydraulic systems - Remote control valves

Remote control valve operating phases to operate the simple action cylinders Float

CUIL15TR00123GA

(1). Static oil (2). Oil being discharged NOTE: To operate the double-acting cylinder, tighten the bolt (3) completely. To operate the simple action cylinder, loosen the bolt (1). (3) When you move the control lever (located in the cab) forward, the rod (10) moves to the position indicated in the figure above. The oil contained in the cylinder, pressurized by the weight of the lifting implement, flows to the return (L) through the gallery (G), while the entire pump flow is directed to the return (L) through the retention valve (3) and gallery (H), since bolt (1) is completely loose serving as a flow deviation (overflow). (9) (8) (4) (6) (5) (3)

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Remote control valve - Remove NOTE: There are different versions of remote control valve. However, the removal procedure follows the same principles. NOTICE: Wash the remote control valves and the areas around the valve before removing the valve. 1. Loosen the nuts (1) together with the terminal supports to allow movement of the tubes (5). Remove the tube (5). 2. Remove the valve return tube (2). 3. Remove the hydraulic lift tube (3). 4. Remove the pressure tube (4) from the main hydraulic pump.

CUIL13TR00727AA

CUIL13TR00725AA

CUIL13TR00784AA

NOTICE: After disconnecting each of the tubes, protect the disconnected ends with suitable covers. 5. Disconnect the control tie rods (1) and (2).

6. Remove the four bolts (1), (2), (3) and (4) and remove the remote control valve from the tractor.

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Remote control valve - Disassemble â&#x20AC;&#x201C; Double-acting cylinder with detent and float control TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Remote control valve - Remove (35.204)

1. Identify all the bodies (1), (2), (3) and (4) of the remote control valve. 2. Secure the assembly of the remote control valve in a vise. NOTICE: When securing control components in the vise, use appropriate protection, such as aluminum jaws. Scratches and deformations can render the parts useless.

CUIL13TR00721AA

CUIL13TR00720AA

3. Remove the four nuts from the tie rods (4) of the valve bodies (1) and (2). NOTE: The valve bodies are manufactured and adjusted together with the spools (5) and (6) in order to provide the correct clearances for proper sealing and operation. Do not mix the spools (5) and (6) with the valve bodies (1) and (2). 4. Remove the bodies (1) and (2). 5. Remove and discard the seal rings (3) between the sections. NOTE: Replace all the rings (3) during assembly. 6. Place the valve body in a vise.

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7. Loosen the fixing bolts, the cover (4) and the separator (3). (4) (3) 8. Repeat this with the fixing bolts and the control lever support cover (1) and its associated seal. (1)

LAIL11TL0838A0A

LAIL11TL0754A0A

9. Remove the rod (3). (1) 10. Remove the seat, the cover and the spring (2) from the return valve. Check the state of the sealants before reassembly.

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Hydraulic systems - Remote control valves

Remote control valve - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Remote control valve - Remove (35.204) .

CUIL13TR00721AA

CUIL13TR00720AA

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Hydraulic systems - Remote control valves

6. Remove the cover (5), the spring cover (4) and the dish spring. (5) (4) 7. Remove the rod (3). (3) 8. Remove the control lever support (1) and the sealant cover (2). (1) (2) 9. Remove the plug (6) and the simple/dual action valve adjustment cap. 10. Remove the valve seat, retention valve cover and the spring. (8) 11. Check the state of the sealants before reassembly. LAIL11TL0837A0A

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Hydraulic systems - Remote control valves

Remote control valve - Test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Remote control valve – Single-acting configuration NOTE: With the testing device full of SAE 10w30 hydraulic oil, the following tests must be performed at an approximate temperature of 60 °C and a flow rate of 12.3 litres/min, which can be obtained using an electric motor as a pump. SAE 10W30 60 °C 12.5 l/min 1. Install the assembly of the remote control valve and the DATAR FLOW METER test equipment as indicated in the figure to the side. 2. The return line (2) must be connected via the power output couplings (1) on the valve control (output located on the opposite side to the switching valve). 3. Operate the hydraulic pump and the hand lever to move the rod. 4. Gradually increase the pressure by turning the handle of the test device and check if the pressure on the gauge reaches 172.0 bar (2494.0 psi). 5. In this condition, the valve control rod must slide normally and return to the neutral position the moment you release the hand lever. 6. Repeat the test on the other control valves after making the appropriate connections.

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LAIL11TL0756A0A

Hydraulic systems - Remote control valves

Remote control valve – Double-acting configuration NOTE: With the testing device full of SAE 10w30 hydraulic oil, the following tests must be performed at an approximate temperature of 60 °C and a flow rate of 12.3 litres/min, which can be obtained using an electric motor as a pump. SAE 10W30 60 °C 12.5 l/min 1. Install the assembly of the remote control valve and the DATAR FLOW METER test equipment as indicated in the figure to the side. 2. The two cylinder outputs must be connected to the ball valve (3) through the tubes (2) and the couplings (1). 3. Operate the hydraulic pump and the hand lever to move the rod. 4. Gradually increase the pressure by turning the knob on the test apparatus and check if the pressure on the pressure gauge reaches 172.0 bar (2494.0 psi). 5. In this condition, the valve control rod must slide normally and return to the neutral position the moment you release the hand lever. 6. Repeat the test on the other control valves after making the appropriate connections.

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LAIL11TL0755A0A

Hydraulic systems - Remote control valves

Remote control valve - Leakage test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Install the remote control valve and the test equipment on the workbench as shown in the figure to the side. Be aware that the three-point connection (1) must be connected to the single-acting and double-acting control valves using the appropriate adapters. 2. Operate the hydraulic pump, gradually increasing the pressure by turning the knob on the test apparatus until you reach a pressure reading of 147 bar (2132 psi) on the pressure gauge. 3. Collect the oil that flows out of the coupling (2) into the burette supplied (3) for exactly one minute. (2) (3) 4. Make sure that the quantity of oil collected does not exceed 0,025 l/min for a new valve or 0,060 l/min for a used valve. 5. Repeat the test for each control valve alternately checking the two feed lines to the cylinder.

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LAIL11TL0757A0A

Hydraulic systems - Remote control valves

Remote control valve - Pressure setting TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Adjusting the pressure in the automatic disarm 1. Connect the remote control (1) to the flowmeter. 2. Activate the hydraulic pump to feed the remote control. 3. Operate the control rod until a constant operational level is attained.

LAIL11TL0756A0A

CUIL14TR01394AA

4. Loosen the bolt for adjusting the pressure relief (1) until the value 170 - 175 bar ( 2465.0 - 2537.5 psi) is displayed. 5. In that condition, the rod should move to the neutral position (disarm) indicating perfect system operation. Secure the bolt (1) into position by tightening the jam nut.

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Index Hydraulic systems - 35 Remote control valves - 204

(*)

Remote control valve - Disassemble â&#x20AC;&#x201C; Double-acting cylinder with detent and float control (*) . . . .

Remote control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Leakage test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valve - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote control valves - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

Hydraulic systems - 35 Three-point hitch control valve - 114

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Contents Hydraulic systems - 35 Three-point hitch control valve - 114

TECHNICAL DATA Three-point hitch control valve General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

FUNCTIONAL DATA Three-point hitch control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

SERVICE Three-point hitch control valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Relief valve Pressure setting â&#x20AC;&#x201C; Valve on the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

(*) See content for specific models 47835583 21/10/2015

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

Reference

PAGE

Three-point hitch control valve - Check

35.5 / 17

Three-point hitch control valve - Install

35.5 / 21

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - General specification Pressure relief valve for high pressure system Clearance between the control rod (8)* and the seat in the valve block control body Clearance between the lift control valve (10)* and its seat Check valve spring (12)* - Free length Check valve spring (12)* - Length under a load of 52 56 N (12 - 13 lb) Main control rod spring (5) * - Free length Main control rod spring (5) * - Length under a load of 31.7 - 35 N (7 - 8 lb) Control valve spring (9)* - Free length Control valve spring (9)* - Length under a load of 103 114.7 N (23 - 26 lb) Arm lowering speed control valve spring (14)* - Free length Arm lowering speed control valve spring (14)* - Length under a load of 67 - 73 N (15 - 16 lb) Lowering speed control valve spring (1)* - Free length Lowering speed control valve spring (1)* - Length under a load of 65 - 71 N (15 - 16 lb) Lowering speed control valve spring (4)* - Free length Lowering speed control valve spring (4)* - Length under a load of 0.9 - 1 N (0 - 0 lb)

TL60E TL75E TL85E TL95E 186.0 - 191.0 bar (2697.0 - 2769.5 psi) 0.008 - 0.012 mm(1) 0.008 - 0.014 mm(1) 25.5 mm 17.5 mm 50.5 mm 34 mm 44 mm 29 mm 34 mm 27 mm 48 mm 32 mm 21 mm 13 mm

(*) See the references in Three-point hitch control valve - Sectional view (35.114). (1)

During assembly, the rods for the valve block control and the control valves are carefully selected to obtain the required clearance.

Three-point hitch control valve - Special tools 380000275 380000274 380000218 380000230 380000217

Control Pilot Valve Seal Guard Union for Checking Distributor Valve Seal Union for Cylinder Safety Valve Calibration Wrench For Cylinder Safety Valve Setting Ring Nut Lift Relief Valve Adapter

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Three-point hitch control valve - Torque

LAIL11TL0952F0A

Reference (C1) (C2) (C3)

Toque 83 N·m (61 lb ft) 83 N·m (61 lb ft) 55 N·m (41 lb ft)

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Exploded view

CUIL13TR00704AA

Reference (1) (2) (3) (4) (5) (6)

Component Valve body Plug seal Screw Washer Plug

Reference (7) (8) (9) (10) (11) (12)

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Component Spool and valve body assembly Spring Plug Seal Sealing rings Hydraulic Valve

Hydraulic systems - Three-point hitch control valve

CUIL13TR00705AA

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

Component Valve body seal Connector seal

Reference (5) (6) (7)

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Component seal Guide ring Piston

Hydraulic systems - Three-point hitch control valve

CUIL13TR00708AA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

Component Valve body seal Valve seat Ball Spring seal seal seal Connector Spacer

Reference (11) (12) (13) (14) (15) (16) (17) (18) (19)

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Component Spacer Ring Pin Special seal Ring Spring Spool seal Relief valve

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Exploded view

CUIL13TR00706AA

Reference (1) (2) (3) (4) (5) (6) (7) (8)

Component Screw seal Nut seal Guide ring Screw Cover cap Plug

Reference (9) (10) (11) (12) (13) (14) (15)

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Component Spring seal seal Plug seal Spool and valve body assembly Valve

Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Sectional view

LAIL11TL1053G0A

Reference

Component

(9)

Control valve return spring

(10) (11)

Command vlalve Check valve

(12)

Retention valve return spring

(5)

Component Actuation speed adjustment valve spring seal seal Actuation speed adjustment valve spring Control valve return spring

(13)

(6)

seal

(14)

(7) (8)

Valve block control rod seat Control rod for the valve block

(15)

Cylinder saftey valve Arm lowering speed adjustment valve spring seal

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

NOTE: To fit sealant rings (2), (3), (6) and (15), heat the corresponding rigid ring in oil to a temperature of around 50 Â°C. 47835583 21/10/2015

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Hydraulic systems - Three-point hitch control valve

When installing sealant (15) and the rigid ring, use protection device 380000266. When installing sealant (6) and the rigid ring, use protection device 380000275. The sealants (2) and (3) and the rigid rings may be fitted without a protection device. However, take the necessary precautions not to damage them.

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Remove Prior operation: Pneumatically-adjusted operator seat - Remove (90.124) . 1. Remove the carpet around the operator seat. 2. Remove the guard plate (1) by removing the six bolts (2) .

CUIL13TR00774AA

CUIL13TR00784AA

3. Remove the pressure tube (3) by loosening the nut (2). 4. Remove the four bolts (1) and remove the lift control valve for the three-point hitch.

Next operation: Three-point hitch control valve - Disassemble (35.114) .

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Disassemble Prior operation: Three-point hitch control valve - Remove (35.114) .

1. Before disassembly, thoroughly clean the control valve block surfaces. Then clamp it in a vice and loosen bolts (1) and (2).

LAIL11TL0818A0A

LAIL11TL0819A0A

LAIL11TL0820A0A

2. Remove the cover from the control valve block (1) and its body (2).

3. Loosen the cover (1) and remove the spring (2) and the control valve (3).

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Hydraulic systems - Three-point hitch control valve

4. Remove the safety valve from the cylinder (4) and remove the arm lowering speed adjustment (3), the spring (2) and the rod (1).

LAIL11TL0821A0A

LAIL11TL0822A0A

LAIL11TL0823A0A

LAIL11TL0824A0A

5. Remove the check valve (1), the spring (2) and the ball (3).

6. Remove the rod from the control valve block (1) and remove the seat (3) and the spring (2).

7. Remove the cover (1) and remove the spring and the oil discharge valve.

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8. Remove the piston from the discharge control valve (1), the spring (3), the ball (2) and the seat (4).

LAIL11TL0825A0A

Next operation: Three-point hitch control valve - Check (35.114) .

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Check Prior operation: Three-point hitch control valve - Disassemble (35.114). 1. Check for wear on the sealants on the seat on the control rod of the valve block. 2. If damaged, re-install the sealants using the guard 380000275 (1). Follow the instructions described in Three-point hitch control valve - Sectional view (35.114).

LAIL11TL0826A0A

LAIL11TL0827A0A

LAIL11TL0828A0A

3. Check the control valve block rod efficiency as indicated below. 4. Install the rod of the control valve block (2) complete with the seat (3) using the tool 380000274 (1).

5. Install the spring in the valve block control rod (1) and the cover (2) of the tool 380000274. Tighten the cover as much as possible and check that the valve block control rod slides in its seat.

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Hydraulic systems - Three-point hitch control valve

6. Fit the tool 380000274 (2) on the manual pump 380000215 (3) providing NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL oil. 7. Assemble a 400 bar pressure gauge (1). Fasten with the bolt.

LAIL11TL0829A0A

LAIL11TL0830A0A

LAIL11TL0831A0A

LAIL11TL0832A0A

8. Activate the manual pump while tightening the bolt (1) with the tool until the oil stops flowing through the valve block control rod seat outlet. 9. Set the comparison gauge to zero. 10. Tighten the screw (1) with the tool to move the valve block control rod further between 1.8 - 2 mm, and use the comparison gauge to measure this distance.

11. Operate the hand pump until the oil in the system reaches an initial pressure of 245.0 bar (3552.5 psi). 12. Use the pressure gauge to check if it takes more than six seconds for the pressure to fall from 196.0 bar (2842.0 psi) to 98.0 bar (1421.0 psi). 13. If it takes less time, reinstall the valve block control rod. Remember that this part should be supplied with the seat.

14. Check the valve block control cover sealants (1) and replace them if damaged.

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Hydraulic systems - Three-point hitch control valve

15. Check the valve block sealants (1) and replace them if necessary. 16. Check the arm lowering speed control sealant, and replace it if it is damaged. Observe the note described in Three-point hitch control valve - Sectional view (35.114).

LAIL11TL0834A0A

LAIL11TL0833B0A

17. Check and adjust the safety valve as shown below. 18. Fit the safety valve cylinder (1) to connection 380000218 (2) and install it on the manual pump 380000215 (3). 19. Activate the manual pump (3) and check that the safety valve opens at a pressure of around 210 215 bar (3045 - 3118 psi). If the valve value does not match the specified value, it is better to replace it. However, if necessary, you can adjust it by turning the cover with the thread using the key 380000230. Tighten to increase the value or loosen to reduce it.

Next operation: Three-point hitch control valve - Check (35.114).

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Assemble Prior operation: Three-point hitch control valve - Check (35.114) .

CAUTION Pinch hazard! Always use suitable tools to align mating parts. DO NOT use your hand or fingers. Failure to comply could result in minor or moderate injury. C0044A

1. See the illustrations in Three-point hitch control valve - Sectional view (35.114) for the positions of the various components. 2. Apply the torques listed in Three-point hitch control valve - Torque (35.114) . 3. Mount the control rod (1) to the complete valve block.

LAIL11TL0823A0A

LAIL11TL0822A0A

LAIL11TL0821A0A

4. Assemble the check valve (1).

5. Assemble the safety valve cylinder (4).

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Hydraulic systems - Three-point hitch control valve

6. Assemble the control valve (3). 7. Assemble the complete pressure control valve. 8. Assemble the valve block control cover.

LAIL11TL0820A0A

Next operation: Three-point hitch control valve - Install (35.114) .

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Hydraulic systems - Three-point hitch control valve

Three-point hitch control valve - Install Prior operation: Three-point hitch control valve - Assemble (35.114). 1. Clean the mating surfaces thoroughly. Apply a layer of LOCTITEÂŽ 515â&#x201E;˘ 2 mm thick to the lift box, as shown in the figure.

CUIL13TR00710AA

CUIL13TR00784AA

CUIL13TR00774AA

2. Install the lift control valve for the three-point hitch. Secure the valve with the four bolts (1). 3. Install the pressure tube (3). Secure the pressure tube with the bolt (2).

4. Install the guard plate (1). Secure the guard plate with the six bolts (2).

Next operation: Pneumatically-adjusted operator seat - Install (90.124).

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Hydraulic systems - Three-point hitch control valve

Relief valve - Pressure setting â&#x20AC;&#x201C; Valve on the tractor The figure 1 shows the location of the lift pressure relief valve (1). The lift pressure relief valve is on the control of this valve block.

CUIL13TR00709AA

LAIL11TL0817A0A

Pressure adjustment 1. Switch the engine on and leave it running until the oil reaches a temperature of around 50 Â°C 2. Install a 250 bar pressure gauge or a flowmeter on the outlet of the remote valve. 3. Activate the remote control lever until the pressure relief valve opens. 4. With the engine at a medium rpm, the pressure gauge should record a pressure of around 186 - 191 bar (2697.0 - 2769.5 psi). 5. If the valve you use does not allow you to adjust the pressure and if the pressure value does not match the recommended value, then replace the valve. NOTE: If the valve model allows you to adjust the pressure: Turn the threaded cap (1). Tighten the cap to increase the pressure value or loosen the cap to decrease the pressure value.

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Hydraulic systems - Three-point hitch control valve

Relief valve - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Lift pressure relief valve On models with open centre system remote control valves, the lift pressure relief valve (1) is located in the control of that valve block. 1. Remove the valve. Test the pressure by following the procedures described in Relief valve - Pressure setting (35.114). 2. If the value found in the test is within specifications, re-install the relief valve in the valve block. If it is not within specifications, replace with a new valve.

CUIL13TR00709AA

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Hydraulic systems - Three-point hitch control valve

Relief valve - Pressure setting TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

The pressure relief valve can be tested and, if required, adjusted on the bench as follows: 1. Fit the pressure relief valve (1) to the connection 380000217 (2) and install the connection on the manual pump 380000215 (3). 2. Activate the manual pump (3) and check that the valve opens at a pressure of around 186 - 191 bar (2697 2770 psi). NOTICE: During assembly, the pressure relief valve is calibrated using the oil flow and the number verified by the manual pump 380000215 is only to be considered an approximation. It is therefore advisable to check the pressure setting of the relief valve with the valve installed on the tractor as described in Relief valve - Pressure setting â&#x20AC;&#x201C; Valve on the tractor (35.114).

LAIL11TL0833B0A

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Index Hydraulic systems - 35 Three-point hitch control valve - 114

(*)

Relief valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief valve - Pressure setting â&#x20AC;&#x201C; Valve on the tractor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Relief valve - Pressure setting (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Assemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Three-point hitch control valve - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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

47835583 21/10/2015 EN

SERVICE MANUAL Hitches, drawbars, and implement couplings TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Hitches, drawbars, and implement couplings - 37

[37.110] Rear three-point hitch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37.1

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Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

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Contents Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

TECHNICAL DATA Rear three-point hitch General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Rear three-point hitch - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Rear three-point hitch Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Adjust of the position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Height adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Adjust â&#x20AC;&#x201C; Constant effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Height adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

DIAGNOSTIC Rear three-point hitch Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

(*) See content for specific models 47835583 21/10/2015

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Type Control system Lift reaction speed adjustment Lift-O-Matic™ Single-acting cylinder – Piston stroke and diameter Capacity Pressure relief valve setting Adjusting the cylinder safety valve Lift piston diameter: Sleeve internal diameter: Play between the piston and sleeve Diameter of the flexion bar Diameter of the flexion bar in the bushing position

TL60E TL75E TL85E TL95E Controlled position, constant effort (undulation) and mixed control Through two independent levers Automatic, through the reaction speed valve located in the valve block Allows for lifting/lowering operation using the buttons, without using the position control or constant effort (undulation) levers 100 mm x 110 mm x 128 mm 128 mm 1005 cm³ 1216 cm³ 190 - 195 bar (2755 - 2828 psi) 210 - 215 bar (3045 - 3118 psi) 99.980 109.980 - 110.000 mm 100.000 mm 100.036 110.036 - 110.071 mm 100.071 mm 0.036 - 0.091 mm 25.870 24.867 - 24.900 mm 26.000 mm 29.967 30.000 mm

Diameter of the lift arm shaft (11)* in the bushing position – Right-hand side Diameter of the lift arm shaft (11)* in the bushing position – Left-hand side Internal diameter of the bushings mounted on the lift cover – Right-hand side (8)* Internal diameter of the bushings mounted on the lift cover – Left-hand side (12)* Play between the lift arm shaft and bushings Interference between the bushings and the cover seats Axial play of the shaft complete with the lift arms External diameter of the constant effort control shaft Internal diameter of the support seats Play between the control shaft and the seat Diameter of the position control shaft Diameter of the position control internal control shaft Play between the constant effort control and position control shafts

55.970 - 55.000 mm 62.670 - 62.700 mm 55.100 - 55.184 mm(1) 62.800 - 62.884 mm(1) 0.100 0.065 0.2 21.967 22.020 0.020 14.973 14.016

Value to be attained after obtaining the interference with no need for machining. 47835583 21/10/2015

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0.214 mm 0.185 mm 1.4 mm 22.000 mm 22.072 mm 0.105 mm 14.000 mm 14.059 mm

0.016 - 0.086 mm

(*) See the references in Rear three-point hitch - Sectional view (37.110). (1)

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Special tools TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

NOTICE: The operations described in this section should only be performed using the ESSENTIAL tools that appear below with the symbol (X). However, for greater safety and to obtain the best results, saving time and effort, we recommend using these essential tools together with the specific tools listed below and certain tools that should be made following the construction designs supplied in this manual. List of specific tools required for the various operations contained in this section. X X X X X X X X X

380000224 380000823 380000225 380000262 293839 380000231 380000267 380000275 380000263 380000264 380000237

Hydraulic lift hook. Installation guide for the 100 mm seal and piston. Installation guide for the 110 mm seal and piston. Retainer fitter on shaft arms. Needle bearing fitter on arms. Wrench for Lift Pressure Relief Setting Ring Nut Wrench for Arms Height Adjustment Control Pilot Valve Seal Guard Controlled Draft Setting Tool Position and Draft Control Setting Tool Lifting hook for the rear wheel. (Use with 380000224)

Rear three-point hitch - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

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Hitches, drawbars, and implement couplings - Rear three-point hitch

LAIL11TL1052G0A

Reference (C1) (C2) (C3) (C4) (C5) (C6) -

Part Fixing bolt for the lift of the rear transmission box Stud nuts for the quadrant levers clamp Fixing bolts for the lift arm plate Fixing bolts for the top link clamp Upper fixing bolts for the lift cylinder Lower fixing bolts for the lift cylinder Fixing bolts for the lift control valve block Fixing bolts for the camshaft Fixing bolt flexing bar support Fixing bolts for the stabiliser side bracket support Fixing bolts for the hitch bracket hook support

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Torque 98 N·m (72.3 lb ft) 25 N·m (18 lb ft) 142 N·m (105 lb ft) 147 N·m (108 lb ft) 260 N·m (192 lb ft) 157 N·m (116 lb ft) 26 N·m (19 lb ft) 147 N·m (108 lb ft) 221 N·m (163 lb ft) 221 N·m (163 lb ft) 221 N·m (163 lb ft)

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Hydraulic schema

CUIL13TR00640AA

1. 2. 3. 4.

Hydraulic gear pump Remote control valves Pressure Relief Valve Hydraulic lift control valve block

5. 6. 7. 8.

Filter Oil being suctioned Pressure Oil Return to deposit

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Neutral phase

CUIL13TR00641AA

1. 2. 3. 4. 5.

check valve Arms lowering speed control valve Cylinder saftey valve Main Stack Valve Piloted valve (discharge)

6. 7. 8. 9.

Reaction speed control valve Static oil Return oil Oil under pressure

When the lift arms reach a certain height, the internal levers stabilize. The main control valve rod position (4) makes the oil pass through the reaction speed control valve (6) and on to the (piloted) control valve (5). (4) (6) (5) The oil pressure over the piloted valve (5) overcomes the resistance of the spring and moves the valve. (5) That creates a discharge opening allowing the oil to flow to the transmission box (reservoir) instead of flowing to the lift cylinder.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Arm lowering phase

CUIL13TR00642AA

A. 1. 2. 3. 4. 5.

Operation with constant effort (undulation) check valve Arms lowering speed control valve Cylinder saftey valve Main Stack Valve Piloted valve (discharge)

6. 7. 8. 9.

Reaction speed control valve Constant effort drive rod Return oil Oil under pressure

When the operator lowers the control lever to the right, the arms lower. The internal levers transmit the movement (shown by the arrows) to the control valve rod (4). (4) The control valve rod (4) is moved down by the spring, enabling the cylinder oil that passes through the control valve which controls the speed of descent of the arms (2), to be limited whilst passing through the opening created by the valve blocking rod. (4) (2) The pressurised oil passes through the valve (6) and drives the control valve piston (5). (6) (5) The piston overcomes the spring resistance and moves the valve, thus creating an output and allowing the oil to flow to the transmission box instead of flowing to the lift cylinder. With the constant effort operation (detail â&#x20AC;&#x153;aâ&#x20AC;?), the lowering control is transmitted by the flexing bar. The bar in turn transmits the movement (shown by the arrows) to the main control valve (4) through the control shaft (7). (4) (7) NOTE: The speed of descent of the implement (2) connected to the lifting arms is controlled by the position of the control valve governing the speed at which the arms are lowered (2). As the control valve bolt (2) is loosened, the outlet passage between the valve and the body of the block is reduced. (2) This means the implement takes longer to lower. The more the bolt is tightened, the wider the discharge aperture becomes, resulting in a faster descent of the implement.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Arm lifting phase

CUIL13TR00639AA

A. 1. 2. 3. 4.

Operation with constant effort (undulation) check valve Arms lowering speed control valve Cylinder saftey valve Main Stack Valve

5. 6. 7. 8. 9.

Piloted valve (discharge) Reaction speed control valve Constant effort drive rod Oil under pressure Return oil

When the operator uses the control lever to their right to lift the arms, the movement shown by the arrow is transmitted by the internal levers to the main control rod (4) in the valve block. This rod interrupts the passage of oil to the control valve (5), which is pushed by the spring at the speed at which the valve is actuated (6). (5) (6) The pressurised oil opens the valve (1) and activates the lifting arms piston. (1) With the application of constant effort (detail â&#x20AC;&#x153;Aâ&#x20AC;?), lift control is conveyed through the flexion bar, which in turn transmits the movement indicated by the arrows to the main control valve (4) in the valve block through the vertical drive rod (7).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Sectional view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

LAIL11TL0953F0A

Reference (G) (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component G = 0.2 - 1.4 mm. (Shaft axial play) Travel limiter adjustment bolt Travel limiter adjustment bolt lock nut Camshaft position limiter Pin for the valve control lever and the Lift-O-Maticâ&#x201E;¢ control Arm washer Thrust Washer Right hand retainer R.H.Bushing. Top connection clamp Internal arms Arm control shaft

Reference (12) (13) (14) (15)

Component Left side bushings Left hand retainer Lift arms Arm washer

(16)

Thrust Washer

(17) (18) (19) (20) (21) (22) (23)

Piston bracket pin Constant effort lever internal control Support Fixing bolt Lock washer Eccentric lever pin (18) Fixing bolt (Allen)

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Description and operation The mechanical lift operates with position, constant effort and mixed control. The lift is controlled by two special levers located to the right of the operator. There is also the Lift-O-Maticâ&#x201E;¢ device which raises and lowers the implements without the need to use the control device of the control levers. Constant effort is done with the flexing bar installed in a special box assembled under the rear transmission. The lower lift arms and the corresponding control shaft are connected to the flexing bar.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

To remove the hydraulic lift from the rear transmission box, proceed as follows: 1. Disconnect the negative cable (1) from the battery.

CUIL13TRO0194AA

LAIL11TL0027A0A

2. Remove the arm from the 3rd point (1).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Loosen the bolts (1) and use a chain and a hook to remove the trailer hitch support (2).

LAIL11TL0028A0A

LAIL11TL0758A0A

LAIL11TL0759A0A

LAIL11TL0767A0A

4. Remove the cotter pins and remove the pin (1). 5. Remove the lift arms (2) and the side stabiliser bars (3).

6. Loosen the two fixing bolts (1) from the articulation union support and remove it along with the support plate (2).

7. Loosen the fitting (1) and loosen the tube (2) from the body of the lift control valve for the three-point hitch.

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8. Release the electric wires (1) from the latch (2) fitted to the lift.

LAIL11TL0768A0A

LAIL11TL0769A0A

LAIL11TL0770A0A

9. Loosen the fixing bolts (1) from the hydraulic lift in the gearbox.

10. Fit the tool 380000237 (1) to the lift and tighten the four bolts (2).

11. Place the support (1) on the tool 380000237 (2). Connect the hook to the support. Raise the hydraulic lift a few centimeters and pull the hydraulic lift backward, tilting the hydraulic lift to remove the breather tube (3) without damaging it.

LAIL11TL0771A0A

Next operation: Rear three-point hitch - Disassemble (37.110) .

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Rear three-point hitch - Remove (37.110) .

To disassemble the hydraulic lift, proceed as follows: 1. Place the hydraulic lift on a mobile workbench (1).

LAIL11TL0772A0A

LAIL11TL0773A0A

2. Loosen the fixing bolts (1) and remove the control valve block of the three-point hitch (2).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. Loosen the two outer bolts which fasten the body to the cylinder. Turn the lift and loosen the side bolt (3). 4. Loosen the fixing bolts (1) on the internal links (2) to the lift cylinder.

LAIL11TL0774A0A

LAIL11TL0775A0A

LAIL11TL0776A0A

LAIL11TL0777A0A

5. Remove the whole cylinder (1) with the piston.

6. Remove the flexible pin from the internal lever. 7. Loosen the nut (1). Then remove the unit complete with the inner linkages and the Lift-O-Maticâ&#x201E;˘ control lever.

8. Remove the fitting ring and remove the internal control lever (1). 9. Loosen the nuts (2) and remove the spring and the fixing flange (4). 10. Remove the fitting ring and remove the lever (3), friction disks, lever (5) and the stub bolts.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

11. Loosen the fixing bolts (1) from the lever support (2).

LAIL11TL0778A0A

LAIL11TL0779A0A

LAIL11TL0780A0A

12. Loosen the eccentric pin (2), the fixing bolt (1), remove the eccentric pin and remove the inner links. 13. Remove the bolt (3), remove the washers (4), remove the lift arm (5) and remove the thrust washers. NOTE: Repeat the procedure for the other lift arm.

14. Release the lift lock internal bolt (1) and loosen the bolt. Remove the shaft (2) and remove the retainers (3).

15. Use compressed air to remove the piston (2) from the cylinder (1).

LAIL11TL0781A0A

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Hitches, drawbars, and implement couplings - Rear three-point hitch

16. Use pin 293839 (1) to place the bearings on the constant effort internal control lever bearings (2). 17. Use pin 293839 to install the valve block control lever bearing.

LAIL11TL0782A0A

Next operation: Rear three-point hitch - Assemble (37.110) .

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Rear three-point hitch - Disassemble (37.110). 1. Using tool 380000823 (2) for model TL60E and tool 380000225 (2) for the other models, assemble the piston (1) on the cylinders (3).

LAIL11TL0783A0A

LAIL11TL0784A0A

2. Assemble the lift arm shaft (2) and the internal arm (1) inside the lift arm, making sure the reference marks line up. Tighten the corresponding tightening bolt.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

3. To avoid damaging the retainer's internal lips, use a flexible metal strip (1) with a size of 200 mm x 90 mm and a thickness of between 0.05 - 0.1 mm. Install the sheet over the shaft and assemble the retainer.

LAIL11TL0785A0A

LAIL11TL0786A0A

LAIL11TL0787A0A

4. Use the stop 380000262 (1) to finish installing the retainers on the arm shaft seats.

5. Install the lift arms (1) on the shaft, making sure the reference marks line up. Fasten them by tightening the bolts.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

6. Install the internal links and the corresponding eccentric pin, fixing them using the bolts. 7. Assemble the lift control lever spacer. 8. Assemble the control lever complete with the friction discs, fitting rings, and stud bolts. 9. Assemble the spring and use the lever fixing flange. 10. Assemble the internal control lever. 11. Assemble the internal linkages and the Lift-O-Maticâ&#x201E;˘ control lever. 12. Assemble and fasten the cylinder complete with the piston. 13. Assemble the inner articulations and fasten them to the cylinder. 14. Install the lift control valve for the three-point hitch. Consult the procedures in Three-point hitch control valve - Install (35.114). 15. Adjust the hydraulic lift cover in accordance with the following procedure.

LAIL11TL0947B0A

Next operation: Rear three-point hitch - Adjust of the position (37.110).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust of the position Prior operation: Rear three-point hitch - Disassemble (37.110) . The following adjustments refer to the lift without the valve block and assembled on a mobile bench. ATTENTION: You must make all adjustments in the order specified. You must keep the Lift-O-Maticâ&#x201E;˘ device turned off until advised otherwise. It is possible to turn off the Lift-OMaticâ&#x201E;˘ in two ways: A. Keep the external control lever (1) locked in the vertical position.

LAIL11TL0788A0A

LAIL11TL0789A0A

LAIL11TL0790A0A

B. Remove the system drive spring (6).

1. Move the position control lever (1) fully forward against the spacers for the bolts for the support that holds the spring. Move the constant effort (undulation) lever (2) fully backwards.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

2. Turn the arm control shaft until there is inner contact with the lift body (hydraulic lift arms fully raised). 3. Mount the tool 380000264 (4) to the lift body.

LAIL11TL0791A0A

LAIL11TL0792A0A

LAIL11TL0793A0A

LAIL11TL0791A0A

4. Use the wrench (1) to loosen the lock nut (4), figure 6.

5. Loosen the limiting bolt (5) until there is no more contact with the control valve lever (3).

6. Using two wrenches (2) and (3), loosen the lock nut (1), figure 6, and tighten or loosen the tie rod of the control valve (2), figure 6.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

7. Adjust so that the end of the tool rod 380000264 is coincident with the outer face.

LAIL11TL0794A0A

LAIL11TL0793A0A

8. Tighten the rod on the lock nut (1).

Next operation: Rear three-point hitch - Height adjust (37.110) .

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Height adjust Prior operation: Rear three-point hitch - Adjust of the position (37.110) 1. Connect the hose (5) with compressed air to tool 380000264 to move the piston to the end of its travel. Use air pressure to keep it in position.

LAIL11TL0795A0A

LAIL11TL0796A0A

2. Using the key 380000267 (1) figure 1, tighten the bolt (5) until the end of the tool rod 380000264 is coincident with the inner face or until 0.5 mm inside. 3. Tighten the locking nut to a torque of 1.5 NÂˇm (1 lb ft). NOTE: Uncouple the compressed air hose and push the lift piston into the cylinder.

Next operation: Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort (37.110) .

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort Prior operation: Rear three-point hitch - Height adjust (37.110) . Proceed as follows: 1. Remove the end of the rod of the constant effort control (3) and fit it into the rod (5) of the tool 380000263 (1). Then, on a flat surface, level the top end of the rod with the top of the tool and lock with the jam nut (4).

LAIL11TL0797A0A

LAIL11TL0798A0A

LAIL11TL0799A0A

2. With the tool 380000264 fitted to the lift body, move the position lever and constant effort lever (1) and (2) fully backwards against the spacer.

3. Remove the bolt (2) that locks the eccentric shaft.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

4. Rotate the eccentric pin (1) backwards.

LAIL11TL0800A0A

LAIL11TL0801A0A

LAIL11TL0800A0A

LAIL11TL0801A0A

5. Fit the tool 380000263 (1) to the lift body. Fasten the tool on the two holes of the cover. 6. Rotate the bolt (2) supported on the internal constant effort lever (3) until the end of the rod of the tool 380000264 is as close as possible to the inner face.

7. Rotate the eccentric pin (1) until the rod of the tool 380000264 is fully inside.

8. Rotate the bolt (2) until the end of the rod is on the inner face of the tool 380000264.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

9. Finally, rotate the eccentric pin (1) until the rod of the tool 380000264 is on the same plane as the outer face.

LAIL11TL0800A0A

LAIL11TL0801A0A

10. Insert the rod of the tool 380000263 (1) adjusted previously into the seat of the constant effort lever.

11. Use a depth micrometer to measure the distance (L2) between the upper surface of the rod and the support surface of the micrometer on the tool 380000263, which should be 22.9 - 23.1 mm .

LAIL11TL0802A0A

LAIL11TL0801A0A

12. If it is not, adjust the arm (3) until you achieve a value of 22.9 - 23.1 mm. NOTE: You must remove the tool 380000263 (1) to adjust the arm (3). Then re-insert the tool 380000263, but do not change the position of the bolt (2) on the tool.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

13. After you have achieved the specified value, tighten the bolt (1) until it locks the plate (2), figure 13, holding the eccentric pin so that it does not move.

LAIL11TL0800A0A

LAIL11TL0803A0A

14. Insert the bolt (3) which was previously removed and secure it with a liquid torque lock. 15. Remove tools 380000263 and 380000264.

Next operation: Rear three-point hitch - Adjust (37.110) .

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust Prior operation: Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort (37.110).

Adjusting the transmission rod of the flexion bar (constant effort) 1. Adjust the bolt (2) for the tool 380000263 so that distance (L5) is 18.3 - 18.5 mm. Lock the bolt with the nut (1) and check the distance (L5).

LAIL11TL0804A0A

LAIL11TL0805A0A

2. Secure the tool to the housing of the rear axle and adjust the rod (3) making sure that the rod supports the tip of the bolt for the tool. NOTICE: The upper face of the rod (3) is over 18.3 18.5 mm the upper face of the rear axle housing.

Next operation: Rear three-point hitch - Install (37.110).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Thoroughly clean and remove any material from the mating surfaces. Apply a layer of sealant approximately 2 mm thick as shown in the figure to the side. 2. Apply the torque recommended in Rear three-point hitch - Torque (37.110). 3. Install the hydraulic lift in the gearbox and tighten the fixing bolts. NOTE: Use the tools 380000224 and 380000237 or similar tools acquired locally. 4. Assemble the electric wires on the latches on the lift body. CUIL13TR00730AA

LAIL11TL0767A0A

5. Install the pressure tube (2) for the three-point hitch control valve. 6. Lift the operator cab/platform, remove the wooden blocks and tighten the cab fixing bolts. 7. Install the Lift-O-Maticâ&#x201E;˘ control rod. 8. Mount the lift control levers to the linkages.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

9. Assemble the breather tubes for the fuel deposit and for the transmission in the operator cab/platform. 10. Install the top articulation clamp and the quick hitch support of the remote control valves. 11. Install the bipolar connection, seven pole connection and ground wire. 12. Assemble the tank for the windshield wash liquid. Connect the tank to the pumps and suppression tubes. 13. Assemble the RH lift arm adjustment unit. 14. Assemble the lift control lever from the ground. 15. Assemble the lift arms and side stabilizer brackets. 16. Mount the third point arm. 17. Connect the negative battery cable.

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CUIL13TR00604AA

Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Adjust Adjusting the articulation position Proceed as follows: 1. Move the position lever (1) completely forward on the quadrant and check that the distance (L) is 15 - 20 mm.

LAIL11TL0806A0A

LAIL11TL0807A0A

LAIL11TL0808A0A

2. Move the outer position control lever (1) fully backward against the spacers, as shown in the figure to the side. 3. Connect the control articulation and if needed adjust its length. 4. Tighten the rod on the lock nut.

Adjusting the constant effort articulation Test conditions: â&#x20AC;˘ Engine running at medium speed. â&#x20AC;˘ Hydraulic oil temperature: 30 - 40 Â°C. 1. Move the position of the control lever (1) completely forward in the quadrant and the constant effort lever (2) to a distance (L1) of 15 - 20 mm from the start of the notch.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

2. Move the constant effort position lever (2) fully backward against the spacers. 3. Connect the control articulation and if needed adjust its length.

LAIL11TL0807A0A

LAIL11TL0809A0A

LAIL11TL0803A0A

LAIL11TL0808A0A

4. Move the constant effort lever (2) to a distance (L2) of 185 - 195 mm from the beginning of the groove and check if the arms begin to lift in this position.

5. If this does not happen, adjust the eccentric pin to this same distance. 6. Tighten the eccentric pin with the mounting bolt (1).

Adjustment of the Lift-O-Maticâ&#x201E;˘ device 1. Move the position of the control lever (1) and the constant effort lever (2) fully to the front of the quadrant.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

2. Lift the arms with the lever (1).

LAIL11TL0810A0A

LAIL11TL0811A0A

3. Tighten the nut (1) until the hydraulic arms lower. 4. With the Lift-O-Maticâ&#x201E;˘ elevation lever still in the same position, loosen the nut (1) until the arms start to rise. 5. Loosen the nut (1) a further turn and a half.

6. Using the levers (1) and (2), lower and raise the arms a number of times to make sure the device is working correctly.

LAIL11TL0810A0A

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Height adjust WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Adjusting the top travel limit of the Lift-O-Maticâ&#x201E;˘device 1. Apply a load to the end of the articulation of the lower arm linking device. 2. Start the engine and keep it running at a medium rpm. 3. Keep the button (1) pressed until the arms are in the articulation position (fully lowered).

LAIL11TL0812A0A

LAIL11TL0813A0A

LAIL11TL0814A0A

4. Move levers (1) and (2) fully forward in the quadrant (fully lowered). 5. Lift the arms to the desired height using the position lever (1).

6. Loosen the lever (1) and turn the mobile sector (2) to the right until the needle touches the Lift-O-Maticâ&#x201E;˘ (3) control lever.

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Hitches, drawbars, and implement couplings - Rear three-point hitch

7. Use the Lift-O-Maticâ&#x201E;˘ control buttons (1) and (2) to lift and lower the arms a few times to ensure correct operation.

LAIL11TL0810A0A

LAIL11TL0813A0A

8. The top travel limit of the arms only applies to the LiftO-Maticâ&#x201E;˘ device and does not affect other lift functions. This means that the arms may be fully lifted using the levers (1) and (2).

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Hitches, drawbars, and implement couplings - Rear three-point hitch

Rear three-point hitch - Troubleshooting Problem Possible Cause The lift does not manage Inefficient retention valve sealant to hold the weight lifted (with the engine running, the load moves up and down constantly, and with the engine switched off the load drops) Oil leaking through the main control valve rod seat (sleeve) sealants Seal between the main control valve rod and seat (sleeve) is defective

Correction Remove, check, clean and replace the corresponding parts if necessary

Replace the sealants

Remove and clean the main control valve rod and seat (sleeve). Replace the set if damaged Oil leaking through the lift piston sealant Replace the sealants Defective sealant or cylinder safety valve Replace or adjust the valve adjusted to a very low value Lift fails to operate Oil filter clogged Replace the filter. Refer to the Operator’s Manual. Control valve locked in the discharge posi- Release the control valve tion Faulty hydraulic pump Service or replace the pump Lift operates suddenly Oil filter clogged Replace the filter. Refer to the Operator’s Manual. Air entering the pump suction line Check that the connections are tight and the sealants are effective Remove the valve, unblock the holes and The lift operates very Control valve discharge points blocked inspect the filter slowly Remove the valve and release it Control valve drive piston stuck Low lifting capacity Pressure relief valve adjusted incorrectly Replace or adjust the valve Cylinder safety valve adjusted incorrectly Adjust the valve and replace if necessary Low pump efficiency (usually combined Service or replace the pump with a considerable increase in lifting time) Oil leaking through the lift piston sealant Replace the piston sealing ring and check for internal cylinder wear: replace if necessary. Adjust properly The pressure relief valve Lift arm travel adjusted incorrectly opens when the lift arms fully reach the top position Foreign material between the ball and Remove the valve, remove the foreign maThe lift operates very seats in the reaction speed control valve terial and inspect the oil filter quickly Reaction speed control valve seats dam- Replace the seats aged Reaction speed control valve piston Remove the valve and release it jammed The lift lowers very Incorrect adjustment of the arm lowering Adjust it correctly quickly speed valve The lift raises very slowly Oil filter clogged Replace the filter. Refer to the Operator’s Manual. Oil leak from the seals with consequent flow Replace all faulty seals loss: piston seals or cylinder line seals Faulty hydraulic pump Perform tests with the flowmeter, service and/or replace the pump if necessary The lift lowers very slowly Incorrect adjustment of the arm lowering Adjust it correctly speed valve Incorrect adjustment of the Lift-O-Matic™ Adjust the drive cable correctly. drive cable Main control valve jammed or scraping Replace the valve, sleeve and its respective sealing rings

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Index Hitches, drawbars, and implement couplings - 37 Rear three-point hitch - 110

(*)

Rear three-point hitch - Hydraulic schema . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Adjust of the position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Height adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Sectional view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Rear three-point hitch - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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

47835583 21/10/2015 EN

SERVICE MANUAL Frames and ballasting TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Frames and ballasting - 39

[39.140] Ballasts and supports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39.1

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Frames and ballasting - 39 Ballasts and supports - 140

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Contents Frames and ballasting - 39 Ballasts and supports - 140

SERVICE Front ballast Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Frames and ballasting - Ballasts and supports

Front ballast - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Remove the fixing cotter pin (1) from the counterweight lock pin. 2. Remove the bolt (2) and remove the front counterweight assembly using an appropriate lifting device.

CUIL13TR00470AA

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Index Frames and ballasting - 39 Ballasts and supports - 140 Front ballast - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Steering TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Steering - 41

[41.200] Hydraulic control components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.1 [41.206] Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.2 [41.216] Cylinders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41.3

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

Reference

PAGE

Power steering control valve - Assemble

41.1 / 21

Power steering pump - Install

41.2 / 11

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Contents Steering - 41 Hydraulic control components - 200

TECHNICAL DATA Hydraulic control components General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Hydraulic control components Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Power steering control valve Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

SERVICE Hydraulic control components Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Power steering control valve Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Steering circuit relief valve Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

DIAGNOSTIC Hydraulic control components Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

(*) See content for specific models 47835583 21/10/2015

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

Reference Power steering control valve - Assemble

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PAGE 41.1 / 21

Steering - Hydraulic control components

Hydraulic control components - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

TL60E

TL75E TL85E TL95E Independent hydrostatic control Fed by hydraulic pump With paper cartridge installed in the pump intake Orbitrol, with rotating valve controlled directly by the steering column: the steering will still working even if the pump is damaged

Type Hydraulic circuit Oil filter Type Relief valve pressure - Models without Auxiliary Front-Wheel Drive (AFWD) Relief valve pressure - Models with Auxiliary Front-Wheel Drive (AFWD)

140.0 - 145.0 bar (2030.0 - 2102.5 psi) 165.0 - 170.0 bar (2392.5 - 2465.0 psi)

Hydraulic control components - Special tools TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

380000618 380000281 380000836

Steering Adapter Fitting Steering seal installer RotoGlyd Variable Power Steering Seal Installation Tool (Danfoss)

Hydraulic control components - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

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Steering - Hydraulic control components

Tightening torques Description Fixing bolt from the hydrostatic steering to the tractor Fixing bolt for the cover of the hydrostatic steering housing Hydrostatic steering control pump fixing bolt Fixing nut from the drive sleeve to the pump drive shaft

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Turnbuckle 3/8 in - 16 UNC M8 x 1 M6 x 1 7/16 in - 20 UNF

Tightening torque 44 N路m (32.5 lb ft) 34 N路m (25.1 lb ft) 8 N路m (5.9 lb ft) 28 N路m (20.7 lb ft)

Steering - Hydraulic control components

Hydraulic control components - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Description and operation The hydrostatic steering system is activated by the oil pressure from the steering pump which is one of the pumping units installed on the right side of the engine. The steering pump is responsible for forming the Steering, Low Pressure (Steering return) and Lubrication circuits (only for tractors with electrohydraulic power take-off). The steering system hydraulic pump receives power from the intermediate gear installed on the central support of the pumps, which in turn is moved by the gear installed on the engine control shaft. The hydraulic pump of the steering system and the pump of the high-pressure hydraulic system have an independent supply. There is a common filter for the two pumps, responsible for retaining contaminants and particles present in the lubricant oil. The steering pump pumps oil to the hydrostatic steering motor (orbitrol) which is activated by the steering column when the operator moves the tractor steering wheel. The pressurized oil in the steering motor (orbitrol) activates a double-acting piston (tractors with rear wheel drive), or activates two double-acting pistons (tractors with auxiliary front wheel drive). The steering motor (orbitrol) is bolted to the steering column and connected to the steering column by a splined shaft and a lock pin. On tractors with four wheel drive, two steering cylinders are used, one for each wheel. The cylinders are fixed to the axle housing and on the trunnion eyelets. The system pressure safety valve is inside the steering motor (orbitrol).

Operation The system is fully hydrostatic so there is no mechanical link between the steering column and the wheels. The oil is sucked up from the rear axle into the pump through a filter, pressurized by the rotation of the steering pump gears and expelled through the pump outlet orifice to the steering motor. The oil received in the steering motor is sent to the actuation cylinder when the tractor steering wheel is moved. The steering motor includes a measuring unit which adjusts the volume of oil supplied to the cylinder so that it is proportional to the angular movement of the steering wheel. The measuring unit in combination with the test valve allows you to drive the tractor even when there is no oil pressurized by the pump â&#x20AC;&#x201C; manual steering.

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Steering - Hydraulic control components

Schematic diagram of steering operation - centred position

LAIL11TL1011F0A

Suction oil Return oil Reference (1) (2) (3) (4) (5) (6)

Pressurised oil (up to 170 bar) Measured oil to the steering piston Component Metering valve Test valve Check valve Pump Filter Return via cooling and lubrication

Reference (7) (8) (9) (10) (11) (12)

Component Pressure retention valve Control valve liner Control valve coil Not available Not available Steering cylinders

Position centred With the steering wheel immobile, the centring springs align the spool and sleeve at neutral. In these conditions, no oil is sent to the steering cylinders. However, the retained oil is transferred between the sides of the left and right curves of the cylinders, letting the wheels react to the terrain to provide feedback to the driver.

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Steering - Hydraulic control components

Schematic diagram of the steering operation - Steering activated:

LAIL11TL1012F0A

Suction oil Supplying the steering motor Return oil

Pressurised oil (up to 170 bar) Measured oil to the steering piston

Turning to the right Reference (1) (2) (3) (4) (5) (6)

Component Metering valve Test valve Check valve Pump Filter Return via cooling and lubrication

Reference (7) (8) (9) (10) (11) (12)

Component Pressure retention valve Control valve liner Control valve coil Not available Not available Steering cylinders

By turning the wheel to the right, the movement of the control valve spool aligns a series of grooves in the sleeve. While turning to the right, the oil flows through the liner along a groove in the valve spool and into a passage in the steering motor housing and led to a measuring unit, as shown in the figure above. The measuring unit is activated by the rotor drive shaft and sends the oil along another series of passages in the spool and the liner, and into the steering cylinder. The return oil from the other end of the cylinder is sent through the spool and the valve sleeve to a return passage in the housing. When turning the steering wheel to the left, the oil flows along the sleeve in a manner similar to that described when turning to the right.

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Steering - Hydraulic control components

Manual Operation In the event of a failure in the steering pump, or loss of oil pressure, the steering system can be put to work manually. Turning the tractor steering wheel activates the measuring unit which forces the oil into the steering cylinder. On the suction end of the measuring unit, the return oil flows from the cylinder and is aspirated through the safety valve to feed the measuring unit. When an extra oil supply is needed, such as when turning left, the additional oil is aspirated from the power steering reservoir through the safety valve to the measuring unit.

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Steering - Hydraulic control components

Power steering control valve - Exploded view

LAIL11TL1005F0A

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

Component Dust cover ring Reflow valve balls Reflow valve pins Body, rotary valve and valve sleeve Retention valve ball Retention valve threaded plug O-ring seal Support ring for the O-ring Thrust bearing components Retaining ring for springs Springs to return the sleeve to the neutral position

Reference (12) (13) (14) (15) (16) (17) (18) (19) (20) (21)

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(22)

Component Rotor control shaft â&#x20AC;&#x201C; sleeve lock pin Cover fixing bolts Retention valve bushing bolt Washers Cover O-ring Rotor and fixed ring for the rotor Thrust plate O-ring Rotor drive shaft Pressure relief valve complete with spring

Steering - Hydraulic control components

Power steering control valve - Exploded view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CUIL13TR00674AA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

Component Retainer Ring Reflow valve balls Reflow valve pins Bearing Retainer Ring Retainer Ring Relief valve Rotary valve Springs to return the sleeve to the neutral position

Reference (10) (11) (12) (13) (14) (15) (16) (17)

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Component Valve spool lock pin Valve sleeve Rotor drive shaft seal seal Rotor and fixed ring for the rotor Rear cover Fixing bolt

Steering - Hydraulic control components

Hydraulic control components - Pressure test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Steering circuit pressure test When the hydrostatic steering system is working, the oil pressure (1) supplied by the steering pump to the steering motor may rise to the maximum pressure of the safety valve of the steering motor, which is 170 bar (tractors with auxiliary front wheel drive) or 145 bar (tractors without auxiliary front wheel drive). The oil return from the steering motor continues through external lines to the oil reservoir or to supply the solenoid valve block, which contains the pressure regulator valve for the low pressure system ( 16.0 - 17.0 bar (232.0 - 246.5 psi)).

LAIL11TL0839A0A

LAIL11TL0840A0A

LAIL11TL0841A0A

As the pressure is regulated, the excess oil in the low pressure circuit runs through the regulating valve to the discharge circuit or, on tractors with an electrohydraulic power take-off, to the lubrication system, which has a limited pressure of between 5.0 - 8.0 bar, adjusted at the regulating valve located on the Power Take-Off (PTO).

Steering Test 1. Start the engine. 2. Adjust the engine rotation to 1000 RPM. 3. Quickly rotate the steering wheel from stop to stop. Check that the steering is working correctly and that there is no delay between the steering wheel being turned and the wheels moving. NOTE: When the steering is at the end of its run, you should hear the safety valve in the steering motor relieve the excess pressure to the tank, and the engine speed should drop to approximately 970 RPM.

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Steering - Hydraulic control components

Power steering control valve - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

To remove the valve for controlling the hydrostatic steering, proceed as follows: 1. Disconnect the negative battery cable. 2. Remove the tool box and the support. 3. Remove the dashboard right and left covers.

LAIL11TL0843A0A

LAIL11TL0844A0A

4. Remove the steering column cover (1).

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Steering - Hydraulic control components

5. Loosen the bolts (1) securing the light control lever on the column.

LAIL11TL0845A0A

LAIL11TL0846A0A

LAIL11TL0847A0A

LAIL11TL0848A0A

6. Disconnect the electric wires (1) from the tractor ignition key.

7. Remove the pin that fastens the column shaft to the hydrostatic steering control valve and remove the four bolts that fasten the control valve.

8. Remove the bolts securing the steering column (1).

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Steering - Hydraulic control components

9. Remove the steering column (1) to provide space to remove the hydrostatic steering unit. 10. Remove the engine hood. Consult the procedures in Hood - Remove (90.100) .

LAIL11TL0849A0A

LAIL11TL0855A0A

LAIL11TL0858A0A

11. Disconnect the two hydrostatic cylinder oil feed and return hoses (1) and remove the latch. 12. Raise the operator cab. Consult the procedures in Cab - Raise (90.150).

13. Remove the complete hydrostatic steering control valve from the front and disconnect the four feed and return hoses from the steering valve.

Next operation: Power steering control valve - Disassemble (41.200).

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Steering - Hydraulic control components

Power steering control valve - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering control valve - Remove (41.200) . To disassemble the hydrostatic steering control valve, proceed as follows: 1. Secure the steering motor housing in a vise using a tube coupling. NOTE: When assembling, the guide pin must be in the same position as it was before. 2. Remove the bolts from the rear cover, the rear cover, and the sealing rings.

LAIL11TL0859A0A

LAIL11TL0860A0A

LAIL11TL0861A0A

3. Remove the measuring unit, the valve plate, and sealing rings. NOTE: Mark the components to facilitate assembly.

4. Remove the rotor drive shaft.

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Steering - Hydraulic control components

5. Unscrew the retainer from the test valve and remove the reflow valve assembly.

LAIL11TL0862A0A

LAIL11TL0863A0A

LAIL11TL0864A0A

LAIL11TL0865A0A

6. Remove the relief valve assembly.

7. Remove the sleeve and valve spool, rings, and needle bearing. NOTE: To prevent the spool lock pin from falling into a gallery of the assembly, assemble and disassemble the assembly with the valve body in the upright position. This will prevent the lock pin from entering one of the galleries and locking the spool on the liner.

8. Remove the sealing ring.

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Steering - Hydraulic control components

9. Remove the control valve spool from the sleeve.

LAIL11TL0866A0A

LAIL11TL0867A0A

10. Remove the centering springs. NOTE: The arrangement of the leaves must remain the same after reassembly. 11. Remove the lock pin from the valve spool. 12. Separate the spool from the control valve sleeve. 13. Remove the seal rings and the support segment.

Next operation: Power steering control valve - Inspect (41.200) .

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Steering - Hydraulic control components

Power steering control valve - Inspect TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering control valve - Disassemble (41.200) . 1. Wash all the parts in a suitable solvent to remove all the foreign particles and dry with compressed air. 2. Inspect the valve sleeve and spool for damage or wear. Burs or scratches can be removed with an extremely fine sandpaper (No. 1200). Make sure all the parts are thoroughly clean before they are assembled.

LAIL11TL0867A0A

LAIL11TL0868A0A

3. Check whether the centralising springs show signs of damage. Replace them if necessary. 4. Install new seal rings during assembly.

Next operation: Power steering control valve - Assemble (41.200) .

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Steering - Hydraulic control components

Power steering control valve - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering control valve - Inspect (41.200) . 1. Install the spool (internal) and sleeve (external) and align the grooves to install the centralizer springs. Install the lock pin of the valve spool.

LAIL11TL0867A0A

LAIL11TL0868A0A

LAIL11TL0869A0A

2. Install the centralizing springs as shown in the figure to the side.

3. Install the centralizing spring retainer and the needle bearing. NOTE: The internal needle bearing race must be positioned with the chamfer facing the spool. NOTE: During assembly, make sure you have installed the ring (1) with the chamfer to the front of the valve liner.

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Steering - Hydraulic control components

4. Lubricate the control valve spool and sleeve before installing the assembly in the steering motor body. 5. Using the special tool 380000281, install the RotoGlyd type seal ring. Before installation, lubricate the tool guide (sealing ring installer) with NEW HOLLAND AMBRA MULTI Gâ&#x201E;˘ HYDRAULIC TRANSMISSION OIL oil.

LAIL11TL0870A0A

LAIL11TL0871A0A

LAIL11TL0872A0A

LAIL11TL0873A0A

6. Place the tool 380000281 (seal guide) on the valve body and push down with a twisting action. 7. After seating the sealing ring, remove the tool segment from the other end of the valve housing.

8. With the sealing ring installed in the motor body, replace the control valve. NOTE: Make sure the drive is in the horizontal position to help assembly.

9. When the control valve is correctly seated, re-install the reflux valves and the test valve holder. Screw the test valve retainer until it is aligned with the housing surface.

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Steering - Hydraulic control components

10. Reassemble the sealing ring and put on the rear cover.

LAIL11TL0874A0A

LAIL11TL0875A0A

11. Make a reference mark on the top of the tooth (1), near the seat (2), to indicate the exact position of the sleeve pin.

12. Fit the rotor camshaft into the valve body. 13. Insert the tool 380000307 to retain and center the rotor transmission shaft between the rotor and the thrust plate and rotate the shaft to assist in coupling the seat and the lock pin installed on the liner (2).

LAIL11TL0876A0A

LAIL11TL0877A0A

14. Proceed by installing the rotor, taking care to ensure the following: A. Every time the hydrostatic steering is disassembled, invert the rotor to reduce wear on the splined coupling. B. In the figure to the side, the rotor ring (stator) has been removed to show the synchronization between the rotor, rotor control shaft, and lock pin. C. Fit the rotor on the transmission shaft, bearing in mind that synchronization is achieved from the alignment, on the axis plane of the lock pin, of the teeth (1) with the center line of one of the rotor compartments.

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Steering - Hydraulic control components

15. Lubricate the two rings (1) with hydraulic oil. Install the rings in the fixed ring seat of the rotor. Install them so as the fixing holes (2) coincide with the holes on the thrust plate.

LAIL11TL0878A0A

LAIL11TL0879A0A

LAIL11TL0880A0A

LAIL11TL0881A0A

16. Install the cover so that the fixing holes match the rotor fixed ring holes.

17. Remove the retention tool 380000307 and fit the special bolt and washer in the retention valve seat.

18. The bolt with lock pin (1) must be mounted in the position (7). Tighten the bolts in two stages. First to a torque of 17.6 NÂˇm and then to a torque of 34.3 NÂˇm, following the crosswise tightening sequence indicated in the figure to the side.

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Steering - Hydraulic control components

19. Install the safety valve assembly, leaving the cover (4) off until the safety valve has been adjusted. 20. Make sure the motor turns freely without any difficulty. NOTICE: Install the orbitrol in a vise. Fill it with oil. With the aid of a rod, rotate the spool to one side and the other. The oil should be expelled through the outlets to the cylinders on the left and right.

LAIL11TL0882A0A

LAIL11TL0883A0A

LAIL11TL0884A0A

LAIL11TL0885A0A

21. Insert a 6 mm Allen key in the bolt to adjust the relief valve pressure. NOTE: The adjustment will be made later on the workbench or on the tractor. Consult the procedures in Steering circuit relief valve - Pressure test (41.200).

22. Tighten the plug (1) with the corresponding sealant, using an 8 mm Allen key to perform the adjustment on the bench or tractor, tightening them to 40 - 60 NÂˇm (29.5 - 44.3 lb ft).

23. Once the unit is assembled, insert the dust guard ring on the control valve body. 24. After fully adjusting the safety valve, re-install the steering motor in the tractor using the four fixing bolts and torque to 12.8 - 19.6 NÂˇm. 25. Reconnect the four oil pipes, steering motor intake and return, and outlet to the right and left cylinders. Apply a torque of 12.8 - 19.6 NÂˇm . 26. Eliminate the air from the system by moving the steering wheel from stop to stop until the system functions correctly.

Next operation: Power steering control valve - Install (41.200) .

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Steering - Hydraulic control components

Power steering control valve - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering control valve - Assemble (41.200) To assemble the control valve, proceed as follows: 1. Install the hydrostatic steering control valve and fasten it with the four bolts. Torque to 25 - 35 NÂˇm. 2. Tighten the four orbitrol feed and return hoses 3. Install the steering column shaft on the hydrostatic steering control valve. 4. Lower the cab. 5. Remove the lock pin from the steering shaft. 6. Assemble the tubes on the hydrostatic steering cylinder by-pass control coupling. 7. Fasten it with the fixing strap. 8. Reinstall the hood supports. 9. Reinstall the two front cab bolts and lay the carpet. 10. Fasten the steering column with the four fixing bolts. 11. Insert the light control lever on the panel, fit the connection elements and fasten the lever with the two bolts. 12. Remake the starter key connections. 13. Assemble the steering column top cover and fasten the lower part with the fixing bolts. 14. Assemble the two steering column side guard covers and fasten them with four bolts. 15. Install the hood on the tractor. 16. Reinstall the tool box supports. 17. Assemble the negative cable on the battery, close the hood and reinstall the exhaust tube. 47835583 21/10/2015

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Steering - Hydraulic control components

Steering circuit relief valve - Pressure test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

NOTICE: There is no safety valve in the steering pump and the following pressure test can only be performed as set out below. Failure to comply with these precautions could result in serious damage to the hydraulic pump. 1. Pressure gauge of 300 bar 2. Hose flexible 3. Adapter 380000618

LAIL11TL0842A0A

1. Turn the steering completely to the left. 2. Install a suitable pressure gauge (1) on the flexible supply tube of the steering piston (left side) using the fittings (2) and (3). 3. Start the engine and adjust its rotation to 1500 RPM. Turn the steering wheel to the left and hold it with a force of 2.25 kgf. Take a reading on the pressure gauge. NOTE: Using a force of more than 2.25 kgf on the steering wheel rim can lead to slightly incorrect readings due to pumping by the hydrostatic steering motor. If the steering test is satisfactory, but the pressure readouts are different from those specified, the steering motor safety valve must be adjusted. The pressure readout should be: â&#x20AC;˘ Tractors with auxiliary front wheel drive (AFWD): 165.0 - 170.0 bar (2392.5 - 2465.0 psi) â&#x20AC;˘ Tractors without AFWD: 140.0 - 145.0 bar (2030.0 2102.5 psi). 4. If the system pressure is not in accordance with specifications, adjust it using the relief valve located on the steering motor. Use a hexagonal 8 mm spanner. Each half a turn of the screw is equivalent to approximately 14.0 bar (203.0 psi). NOTE: To have access to the screw to adjust the pressure on the steering circuit it is necessary to remove the steering motor from the fixation support. 47835583 21/10/2015

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Steering - Hydraulic control components

Hydraulic control components - Troubleshooting NOTE: See the component references in Power steering control valve - Exploded view (41.200) and Power steering control valve - Exploded view (41.200). Problem Oil leak from the hydrostatic steering unit: a. Control side b. Cover side

Steering heavy

Excessive steering play

Steering wheel turns normally but the steering is: a. slow b. no steering

When the engine is off, the wheels do not move when turning the steering.

Possible Cause Faulty valve body O-ring sealant

Correction Replace the sealant and sealing ring using special tool 380000836

Rear cover mounting bolts are not tight enough Faulty rotor seal washers or O-rings Hydraulic pump ineffective Check whether the valve is being kept open by any foreign material or by the absence of the ball Pressure relief valve incorrectly adjusted

Tighten the bolts to the recommended torque 24 - 36 NÂˇm (17.7 - 26.6 lb ft). Replace the washers and the O-rings Repair the pump Eliminate foreign materials and clean the filter: install a ball in the seat (if missing)

Adjust the valve. Consult the procedures in Steering circuit relief valve - Pressure test (41.200) . Pressure relief valve jammed or kept open Eliminate foreign materials and replace the by foreign materials hydraulic filter The steering column is stiff at the bushings Clean, remove rust and replace the bushdue to rusting, jamming, etc ings Excessive play between the column and Replace worn parts the coupling with the rotary valve Excessive play in the coupling between the Replace worn parts rotor drive shaft and the lock pin Excessive play in the splined coupling be- Replace worn parts tween the rotor drive shaft and the rotor Combination of the excessive plays men- Replace most of the worn parts tioned above Replace the springs Blade springs broken or fatigued Replace the sealant Control cylinder sealant damaged.

Broken cylinder rod Replace the damaged part Rotor camshaft or sleeve lock pin broken Replace the damaged part Excessive wear between the rotor and the Replace the damaged parts fixed ring

Retention valve damaged The steering wheel jumps, Incorrect synchronisation of the hydrostatic steering is uncontrollable, steering the wheels turn in the opposite direction from that desired The cylinder connection hoses are inverted The wheels do not keep Worn hydraulic cylinder piston sealant the desired alignment and constant correction with the steering wheel is needed Reflux valve damaged or stuck open by foreign material Mechanical wear to the control valve

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Replace the control valve Synchronise correctly

Fix the connections Replace the sealant

Eliminate foreign materials, replace the filter or replace the control valve Replace the control valve

Steering - Hydraulic control components

Problem Possible Cause Blade springs to return the sleeve to the Not possible to find the hydrostatic steering neutral position are broken or fatigued neutral position. During manual control operation is normal; when manual control is interrupted, the steering wheels turns by itself or remains stopped but the steering remains to the side to which it was turned initially, and therefore the steering wheel must be corrected continuously. Sleeve or rotary valve blocked or in the distribution position due to foreign materials Rotary valve sleeve crushed by excessive pressure

Correction Replace the set of blade springs

Eliminate the foreign materials and replace the filter Check the pressure relief valve adjustment. Consult the procedures in Steering circuit relief valve - Pressure test (41.200). Front wheels vibrating Air bubbles in the hydraulic cylinder Bleed the air and eliminate the possible causes for it entering Worn steering bar mechanical joints Replace worn parts Reflux valve damaged or stuck by foreign Remove foreign materials and replace the material filter, or replace the control valve Insufficient pressure Check the hydraulic pump and the pressure Difficulty steering in relief valve adjustment. Consult the progeneral, or steering in one cedures in Steering circuit relief valve direction Pressure test (41.200). Excess leaks inside the control valve Replace the control valve

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Index Steering - 41 Hydraulic control components - 200

(*)

Hydraulic control components - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Special tools (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Hydraulic control components - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Exploded view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Inspect (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering control valve - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Steering circuit relief valve - Pressure test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

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Steering - 41 Pump - 206

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Contents Steering - 41 Pump - 206

TECHNICAL DATA Power steering pump General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

FUNCTIONAL DATA Power steering pump Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Power steering pump Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

(*) See content for specific models 47835583 21/10/2015

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

Reference Power steering pump - Install

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PAGE 41.2 / 11

Steering - Pump

Power steering pump - General specification Tractors with Auxiliary Front Wheel Drive (4WD) Type Position Manufacturer Drive Rotation (seen from the drive side) Ratio between engine/pump rpm Maximum rpm (engine at maximum power) Corresponding rated capacity Nominal capacity 1000 RPM Diameter of drive and driven gear shafts Bearing housing bushes on the supports Play between the gear shafts and the bushings Maximum play from wear Radial play of gears in pump housing Maximum wear in the pump housing, on the intake side, near the gears Gear width (8)* Width of the journals Width of pump housing for bushings and supports (5)* End play of gears complete with supports in pump housing (must also be established during servicing)

TL60E TL75E TL85E TL95E Pump with spur gears, using the oil from the rear transmission box Coupled to the right-hand side of the engine, activated simultaneously with the hydraulic system pump NEW HOLLAND With gear, directly from the engine Anti-clockwise 1:0.931 2328 RPM 34.5 l/min 14.8 l/min 17.400 - 17.418 mm 17.450 - 17.470 mm 0.032 - 0.070 mm 0.1 mm 0.020 - 0.064 mm 0.1 mm 24.000 - 24.015 mm 24.490 - 24.510 mm 73.135 - 73.160 mm 0.100 - 0.180 mm

(*) See the references in Power steering pump - Exploded view (41.206).

Power steering pump - General specification Tractors without Auxiliary Front Wheel Drive (AFWD) Type Position Manufacturer Drive Rotation (seen from the drive side) Ratio between engine/pump rpm Maximum rpm (engine at maximum power) Corresponding rated capacity Nominal capacity 1000 RPM Diameter of drive and driven gear shafts Bearing housing bushes on the supports Play between the gear shafts and the bushings Maximum play from wear Radial play of gears in pump housing Maximum wear in the pump housing, on the intake side, near the gears Gear widths Width of the journals

TL75 Pump with spur gears, using the oil from the reservoir located over the engine Coupled to the right-hand side of the engine, activated simultaneously with the hydraulic system pump NEW HOLLAND With gear, directly from the engine Anti-clockwise 1:0.931 2328 RPM 26.5 l/min 11.35 l/min 17.400 - 17.418 mm 17.450 - 17.470 mm 0.032 - 0.070 mm 0.1 mm 0.020 - 0.064 mm

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0.1 mm 18.323 - 18.348 mm 19.796 - 19.812 mm

Steering - Pump

Width of pump housing for journals and supports End play of gears complete with supports in pump housing (must also be established during servicing)

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58.072 - 58.122 mm 0.100 - 0.180 mm

Steering - Pump

Power steering pump - Exploded view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CUIL13TR00711AA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Safety washer Rear cover bolt Rear cover Retainers Pump body Bearing housings Driven gear shaft

Reference (8) (9) (10) (11) (12) (13) (14)

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Component Driven gear shaft Key Bearing housings Retainers Front cap Retainer Lock ring

Steering - Pump

Power steering pump - Remove 1. Remove the bolts (1) and remove the suction tube (2) from the pump.

CUIL13TR00693AA

CUIL13TR00331AA

CUIL13TR00782AA

2. Remove the tube bolts (1) and remove the tube.

3. Remove the pump fixing bolts (1). Remove the pump from its housing. NOTICE: Protect the ends of the tube and the pump inlet with suitable covers.

Next operation: Power steering pump - Disassemble (41.206) .

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Steering - Pump

Power steering pump - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering pump - Remove (41.206). 1. Remove the fixing bolts (2) for the cover (3) and the washers (1). 2. Remove the ring (14), the retainer (13), the front cover (12), and the respective lock. 3. Mark the parts (5), (6), (7), (8), (10) and (12) so as to assemble them in the same position, if they are in good condition. 4. Remove the journals (10) and (6), and the gears (8) and (7). 5. Separate the sealants and the anti-extrusion rings (4) and (11). CUIL13TR00711AA

Next operation: Power steering pump - Check (41.206).

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Steering - Pump

Power steering pump - Check TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering pump - Disassemble (41.206) . With the pump disassembled, proceed as follows: 1. Check if the gear and bushings contact faces are flat and perpendicular by inserting a fine carbon sheet between the parts. Small surface differences can be removed with fine lubricated sandpaper. 2. Check that the bearings in the pump gear assembly have play between 0.100 - 0.180 mm. If needed, rework the surfaces using a fine lubricated sandpaper, removing as little material as possible. 3. Thoroughly clean all pump parts.

LAIL11TL0902A0A

CUIL13TR00711AA

4. Replace the sealants (4) and (11). 5. Lubricate the parts with the same oil used in the hydraulic circuits.

Next operation: Power steering pump - Assemble (41.206) .

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Steering - Pump

Power steering pump - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Power steering pump - Check (41.206) . 1. Carry out the assembly as follows: 2. Install the pump, carrying out the disassembly procedures in reverse order. NOTICE: Keep the work area and the parts completely clean. Any foreign body inside the pump could cause serious damage. 3. Install the parts (5), (6), (7), (8), (10) and (12), aligning the positioning marks made before disassembly. 4. Install the gear journals (6) and (10) in the pump body so that the cover on the outer perimeter of the journal is aligned with the distribution line and so that the lubrication fitting faces are in contact with the gears. 5. Install the sealants (4) and (11) together with their respective spacers. Fill the cavity between the sealing points with industrial petroleum jelly grease. Next operation: Power steering pump - Remove (41.206)

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CUIL13TR00711AA

Steering - Pump

Power steering pump - Install Prior operation: Power steering pump - Assemble (41.206) . 1. Fill the suction tube and pump with NEW HOLLAND AMBRA MULTI Gâ&#x201E;¢ HYDRAULIC TRANSMISSION OIL oil to help compression and avoid the risk of breakage during initial operation. 2. Install the four bolts (1) for fixing the pump. 3. Install the pressure tube. Secure the pressure tube with the bolts. NOTE: Make sure you install new tube seal rings.

CUIL13TR00782AA

CUIL13TR00718AA

4. Install the pump suction tube. Secure the pump suction tube with the bolts (2). NOTE: Make sure you install a new seal ring (1).

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Index Steering - 41 Pump - 206

(*)

Power steering pump - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - Check (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Power steering pump - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Steering - 41 Cylinders - 216

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Contents Steering - 41 Cylinders - 216

FUNCTIONAL DATA Steering cylinder Steering cylinder - Exploded view - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . 3 Steering cylinder - Exploded view – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . . . . . 4 Steering cylinder - Exploded view – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . . . . . 5

SERVICE Steering cylinder Remove - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Disassemble - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Inspect - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Assemble - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Install - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Remove – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Disassemble – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Check – Version with Auxiliary Front Wheel Drive (FWD) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Clearance – Version with Auxiliary Front Wheel Drive (FWD) (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Steering - Cylinders

Steering cylinder - Exploded view - Version without Auxiliary Front Wheel Drive (AFWD)

LAIL11TL1044G0A

Reference (1) (2) (3) (4) (5) (6)

Component Piston and connecting rod assembly Cylinder Extension tube Track connecting rod end Dust seal ring Clamp bolt

Reference (7) (8) (9) (10) (11) (12)

Component Staple Nut Sealing ring kit* Nut Track connecting rod end Clamp bolt

(*) The seal ring kit consists of seal rings for the tie rods and bushings, seal rings for the piston, and seal rings for the gland.

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Steering - Cylinders

Steering cylinder - Exploded view â&#x20AC;&#x201C; Version with Auxiliary Front Wheel Drive (FWD)

LAIL11TL1008F0A

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

Component Cylinder Wiper seal Locking ring Seal nut

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

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Component Cylinder connecting rod Bushing and seal set Piston Nut

Steering - Cylinders

Steering cylinder - Exploded view â&#x20AC;&#x201C; Version with Auxiliary Front Wheel Drive (FWD)

LAIL11TL1007F0A

Reference (1) (2) (3)

Component Articulated pin Articulated pin D washer

Reference (4) (5) (6)

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Component Spacer Spacer Locking ring

Steering - Cylinders

Steering cylinder - Remove - Version without Auxiliary Front Wheel Drive (AFWD) WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Loosen the connections for the oil feed and the hoses (1) on the cylinder (2).

LAIL11TL0886A0A

LAIL11TL0887A0A

LAIL11TL0888A0A

2. Remove the nut fastening the cylinder terminal to the arm (1).

3. Using the extractor (1), remove the cylinder terminal from the cylinder rod.

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Steering - Cylinders

4. Remove the pin fixing the cylinder to the shaft body and remove the cylinder (1).

LAIL11TL0889A0A

Next operation: Steering cylinder - Disassemble - Version without Auxiliary Front Wheel Drive (AFWD) (41.216)

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Steering - Cylinders

Steering cylinder - Disassemble - Version without Auxiliary Front Wheel Drive (AFWD) Prior operation: Steering cylinder - Remove - Version without Auxiliary Front Wheel Drive (AFWD) (41.216) . 1. Drain all of the oil from the cylinder and cover the ends. 2. Loosen the clamp bolts (1)and remove the ball joint assemblies (2). 3. Install the appropriate adaptations to the cylinder's orifices to fix it in a vice. NOTICE: Do not fasten directly around the cylinder, as the assembly may be damaged.

LAIL11TL0890A0A

LAIL11TL0891A0A

CUIL13TR00719AA

4. With a C-hook type wrench (2), rotate the cover until the wire (3) appears in the orifice of the liner.

5. Continue rotating the rear cover and with the aid of a screwdriver, lift the end of the wire. Rotate the cover until all the wire is out of the cylinder. 6. Remove the front cover and the piston/tie rod assembly from the cylinder. 7. Replace all of the sealing rings.

Next operation: Steering cylinder - Inspect - Version without Auxiliary Front Wheel Drive (AFWD) (41.216) .

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Steering - Cylinders

Steering cylinder - Inspect - Version without Auxiliary Front Wheel Drive (AFWD) Prior operation: Steering cylinder - Disassemble - Version without Auxiliary Front Wheel Drive (AFWD) (41.216) . 1. Wash all of the components with a suitable solvent and let them dry in the open air. 2. Inspect all of the parts for wear and damage. Small burrs and filings can be removed with extremely fine sandpaper (No. 1200). 3. Check that there is play in the ball joints. Replace them if necessary.

LAIL11TL0892A0A

LAIL11TL0890A0A

4. Replace all the seal components and the lock wire (3).

Next operation: Steering cylinder - Assemble - Version without Auxiliary Front Wheel Drive (AFWD) (41.216) .

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Steering - Cylinders

Steering cylinder - Assemble - Version without Auxiliary Front Wheel Drive (AFWD) WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Install new seal rings (4) for the piston and wear segments (1) in the piston (2) .

LAIL11TL0892A0A

LAIL11TL0893A0A

LAIL11TL0894A0A

2. Install the new seal rings (3) on the front cover. Make sure that the seal lip is facing in the direction of the oil pressure. Install a new seal ring (4) and the tie rod wipers (2).

3. Lubricate the seal rings and slide the front cover assembly (2) inside the piston tie rod (1). NOTE: Special care is needed to install the piston sealing ring on top of segment 'O'. Allow the sealing ring to contract naturally before installing the piston assembly and connecting rod on the cylinder.

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Steering - Cylinders

4. Place the front cover (3) in the vertical position and insert the piston/tie rod assembly and front cover.

LAIL11TL0895A0A

LAIL11TL0893A0A

5. Rotate the rear cover until the spline orifice of the lock ring (5) is visible through the opening in the liner. 6. Insert a new lock wire (5) so that the folded end fits into the spline orifice. NOTE: Make sure that the two splines of the cylinder wall and of the front cover are aligned. 7. Rotate the front cover until the lock wire is wound completely around the cover. 8. Screw the cover (1) onto the cylinder liner until seated completely.

Next operation: Steering cylinder - Install - Version without Auxiliary Front Wheel Drive (AFWD) (41.216) .

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Steering - Cylinders

Steering cylinder - Install - Version without Auxiliary Front Wheel Drive (AFWD) WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

1. Assembly of the steering cylinder and of the control tie rods for the rail is performed in reverse order to the removal process. 2. Bolt the ball joint of the anchor end to the extension tube. Unscrew the ball joint a fraction of a turn and make sure that the joints are well positioned as in the figure to the side. Tighten to a torque of 43.1 N·m (31.8 lb ft). 3. Compress the cylinder connecting rod until the piston touches the bottom of the cylinder.

LAIL11TL0896A0A

LAIL11TL0897A0A

LAIL11TL0898A0A

4. Install the ball joint on the anchor end of the tie rod/shaft of the rail. Tighten to a torque of 176.4 N·m (130.1 lb ft). 5. Position the right wheel with the steering wheel turned fully to the right. 6. Extend the cylinder connecting rod from the completely compressed position to 4.0 - 10.0 mm. 7. Adjust the piston connecting rod ball joint to align it with the track connecting rod saddle. Install the joint (1). Tighten the joint to 176.4 N·m (0.0 lb ft).

8. Position all of the wheels so that they are aligned forwards. Adjust the tie rod of the rail to achieve a divergence of 0 - 13.0 mm measured on the wheel rim at the height of the cover, measurement (A) minus measurement (B). 9. Eliminate the air from the system by switching on the motor and turning the wheels from stop to stop several times. Repeat the operation until the steering works correctly.

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Steering - Cylinders

Steering cylinder - Remove â&#x20AC;&#x201C; Version with Auxiliary Front Wheel Drive (FWD) WARNING Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in death or serious injury. W0208A

Prior operation: Front wheels - Remove (44.511) . 1. Put the tractor on a flat surface and apply the parking brake. 2. Disconnect the flexible tubes, plug the open ends of the tubes, removing their clamps. NOTE: The position of the flexible tubes and the orientation of the joints must be the same after reinstallation. 3. Remove the lock ring (6) securing the steering arm to the articulated pin of the cylinder piston. Remove the articulated pin. 4. Remove the fixing bolt from the articulated pin attached to the end of the steering cylinder, removing the pin (1). Remove the cylinder from the vehicle.

LAIL11TL1007F0A

Next operation: Steering cylinder - Disassemble â&#x20AC;&#x201C; Version with Auxiliary Front Wheel Drive (FWD) (41.216) .

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Steering cylinder - Disassemble – Version with Auxiliary Front Wheel Drive (FWD) Prior operation: Steering cylinder - Remove – Version with Auxiliary Front Wheel Drive (FWD) (41.216) . 1. Using a ‘C’ hook, unscrew and remove the sealing nut. 2. Using a punch, push the front cover of the steering cylinder inside the cylinder and remove the lock ring. 3. Pull the rod assembly and the front cover of the cylinder. 4. Remove the cylinder rod nut and disassemble the cylinder to replace the seal rings.

LAIL11TL0900A0A

Next operation: Steering cylinder - Check – Version with Auxiliary Front Wheel Drive (FWD) (41.216) .

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Steering - Cylinders

Steering cylinder - Check – Version with Auxiliary Front Wheel Drive (FWD) TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Steering cylinder - Disassemble – Version with Auxiliary Front Wheel Drive (FWD) (41.216) . 1. Inspect the cylinder bore and replace it if scratched. 2. Replace all cylinder seal components. 3. Assemble the cylinder in reverse order to the disassembly process, lubricating all of the components as they are assembled. 4. Install the cylinder in the tractor by following the reverse order described in Steering cylinder - Remove – Version with Auxiliary Front Wheel Drive (FWD) (41.216). Next operation: Steering cylinder - Clearance – Version with Auxiliary Front Wheel Drive (FWD) (41.216) .

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Steering - Cylinders

Steering cylinder - Clearance – Version with Auxiliary Front Wheel Drive (FWD) TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Two steering stops are incorporated in the axle, one at each end. The stops are adjustable and must be adjusted to provide a minimum clearance of 20 mm (0.8 in) between the tires and all parts of the machine whenever the steering wheel is fully turned to the left or fully turned to the right. To adjust the steering angle, proceed as described below:

BRAG12TRLUE0482

BRAG12TRLUE1279

1. Turn the wheels fully to the right or fully to the left. 2. Loosen the cotter nut (2) and adjust the screw length (1). 3. To obtain the steering angle required, consult the tables below. Having obtained the desired angle, loosen the cotter nut (2). NOTE: Whilst making this adjustment, take into consideration the fact that the end of the stop's travel should not reach the end of the hydraulic cylinder's travel.

Steering angle (TL60E and TL75E models with Auxiliary Front Wheel Drive – AFWD) Steering angles 25 ° 30 ° 35 ° 40 ° 45 ° 50 ° 55 °

Length (L) mm 57 mm 47 mm 37 mm 28 mm 19 mm 9 mm 0 mm

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in 2,24 in 1,85 in 1,45 in 1,10 in 0,74 in 0,35 in 0 in

Steering - Cylinders

Steering angle ( TL85E and TL95E models with AFWD) Steering angles 25 ° 30 ° 35 ° 40 ° 45 ° 50 ° 55 °

Length (L) mm 63 mm 53 mm 42 mm 32 mm 21 mm 11 mm 0 mm

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in 2,48 in 2,08 in 1,65 in 1,25 in 0,82 in 0,43 in 0 in

Index Steering - 41 Cylinders - 216

(*)

Steering cylinder - Assemble - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . .

Steering cylinder - Check – Version with Auxiliary Front Wheel Drive (FWD) (*) . . . . . . . . . . . . . . . .

Steering cylinder - Clearance – Version with Auxiliary Front Wheel Drive (FWD) (*) . . . . . . . . . . . . .

Steering cylinder - Disassemble - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . .

Steering cylinder - Disassemble – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . .

Steering cylinder - Exploded view - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . .

Steering cylinder - Exploded view – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . .

Steering cylinder - Inspect - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . .

Steering cylinder - Install - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . . . .

Steering cylinder - Remove - Version without Auxiliary Front Wheel Drive (AFWD) . . . . . . . . . . . . . .

Steering cylinder - Remove – Version with Auxiliary Front Wheel Drive (FWD) . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Wheels TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Wheels - 44

[44.511] Front wheels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.1 [44.520] Rear wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44.2

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Wheels - 44 Front wheels - 511

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Contents Wheels - 44 Front wheels - 511

TECHNICAL DATA Front wheels General specification - Compatibility table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Front wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

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Wheels - Front wheels

Front wheels - General specification - Compatibility table The compatibility table shows the combinations that you can use when you choose new tractor tires. Cells with “X” indicate released combinations of front and rear tires. Empty cells indicate combinations that have not been tested or released. NOTE: Never use tires from unapproved combinations. NOTICE: If the tire measurement is not in the tables, see your NEW HOLLAND dealer. Table 01: Acronyms Acronym G T R F P STR CSG II SAT FWD S-ARZ R1 MANUF R.T.

Meaning Goodyear Titan Trelleborg Firestone Pirelli ST Radial Champion Spade Grip II Super All Traction FWD Super Rice Tire Normal grip Manufacturer Rear Tires

Acronym SAT 23 PWT DYT II DYT III TFR STR T 414 TRC-CA CGG R2 CAP F.T.

(*) Tire not indicated for use with front loader or other equipment.

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Meaning Super All Traction 23 ° Power Torque Dyna Torque II Dyna Torque III Traction Field&Road ST Radial Twin 414 Cultivator Tractor Champion Guide Grip High grip Load capacity Front Tires

CAP

6 PR

10 PR

6 PR

10 PR

Measure

13.6X38 R1

16.9X28 R1

18.4X30 R1

18.4X30 R2

23.1x26 R2

R.T. DYT II TRC-CA PWT TM 75 DYT II TFR SAT FWD TM 95 PWT DYT II TM 95 SAT 23 TFR PD 22 CSG II S-ARZ PD 22 CSG II

Check the acronyms in Table 01

CAP F.T. MANUF G G G P G F F P G G P F F P F G P F

Measure

X X

*11.2x24 R1 6 PR DYT II G

X X X X

DYT II G X X X X

X X

12.4x24 R1 6 PR CGG SAT 23 F F X X

X X X

TM 95 P X X X X

Table 02: Compatibility table for the front and rear tires for the TL60E model with a 1.377 transmission rate

X X X

DYT II G

X X X

14.9x24 R1 6 PR TM 95 P

X X X

SAT 23 F

Wheels - Front wheels

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6 PR

10 PR

18.4X30 R2

18.4x34 R1

23.1x26 R2

10 PR

16.9X28 R1

10 PR

6 PR

13.6X38 R1

18.4X30 R1

CAP

Measure

R.T. DYT II TRC-CA PWT TM 75 DYT II TFR SAT FWD TM 95 (8PR) PWT DYT II TM 95 SAT 23 TFR PD 22 CSG II DYT II TM 95 SAT 23 S-ARZ PD 22 CSG II

Check the acronyms in Table 01

X X X X X

G G P F F P F G P F G P F

*11.2x24 R1 6 PR DYT II G

CAP F.T. MANUF G G G P G F F

Measure

X X X X

X X X

DYT II G

X X X

12.4x24 R1 6 PR CGG SAT 23 F F X X X X X X X X

X X X X

TM 95 P X X X X

X X X X X X

DYT II G

Table 03: Compatibility table for the front and rear tires for the TL75E model with 1.357 transmission ratio

X X X X X X

14.9x24 R1 6 PR TM 95 P

X X X X X X

SAT 23 F

X X

14.9x24 R2 6 PR PD 22 S-ARZ P G

Wheels - Front wheels

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CAP

R.T.

13.6X3 8 6 PR R1

DYT II TRC-CA PWT TM 75 DYT II TFR (8 PR) SAT FWD 16.9X2 (8 PR) 8 10 PR R1 TM 95 (8 PR) PWT DYT II 18.4X3 TM 95 0 10 PR SAT FWD R1 TFR 18.4X3 PD 22 0 6 PR CSG II R2 DYT II 18.4x34 10 PR TM 95 R1 SAT 23 S-ARZ 23.1x26 10 PR PD 22 R2 CSG II

Measure

Check the acronyms in Table 01

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G P F G P F

G G P F F P

G G G P G F

MANUF

Measure CAP F.T.

X X X X

X X X

DYT II

X X X

X X X X

X X X

X X X X

12.4x24 R1 6 PR CGG SAT 23

X X X X

TM 95

X X X X X X

DYT II

X X X X X X

14.9x24 R1 6 PR TM 95

X X X X X X

SAT 23

Table 04: Compatibility table for the front and rear tires for the TL85E and TL95E models with 1.357 transmission ratio

X X

14.9x24 R2 6 PR PD 22 S-ARZ

Wheels - Front wheels

Front wheels - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Enter the wedges (1) on one of the sides of the shaft articulation to prevent it from oscillating or lifting the tractor (use a hydraulic jack if necessary).

LAIL11TL0489A0A

CUIL13TR00801AA

LAIL11TL0491A0A

2. Place two nylon cables (1) around the front axle and fasten the cables to the lifting hook.

3. Raise the tractor using the lifting hook (or using a hydraulic jack beneath the tractor) and place a support under the engine sump.

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Wheels - Front wheels

4. Loosen the bolts and remove the front wheels.

LAIL11TL0043A0A

Next operation: Front wheels - Install (44.511) .

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Wheels - Front wheels

Front wheels - Install Prior operation: Front wheels - Remove (44.511) 1. With the front part of the tractor suspended by cables, install the front wheels.

LAIL11TL0043A0A

LAIL11TL0491A0A

LAIL11TL0489A0A

2. Raise the tractor and remove the support under the engine crankcase.

3. Remove the lifting cables bolts from the front axle. 4. Remove the wedges (1).

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Index Wheels - 44 Front wheels - 511 Front wheels - General specification - Compatibility table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Front wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Wheels - 44 Rear wheels - 520

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Contents Wheels - 44 Rear wheels - 520

SERVICE Rear wheels Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Wheels - Rear wheels

Rear wheels - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Lock the front wheels using chocks. 2. Remove the arm (1) and the left stabilizer support (2).

LAIL11TL0002A0A

LAIL11TL0003A0A

LAIL11TL0007A0A

3. Lift the rear part of the tractor and place a fixed trestle under the flexing bar support.

4. Remove the cap screws (1). 5. Remove the left-hand side rear wheel. NOTE: If necessary, follow the same procedures for the wheel on the right-hand side.

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Index Wheels - 44 Rear wheels - 520 Rear wheels - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Cab climate control TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Cab climate control - 50

[50.100] Heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.1 [50.104] Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.2 [50.200] Air conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50.3

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CONSUMABLES INDEX Consumable R134a R134a R134a R134a R134a R134a R134a R134a R134a R134a R134a

Reference Air conditioning - General specification Air conditioning - Dynamic description Air conditioning - Dynamic description Air conditioning - Dynamic description Air conditioning - Dynamic description Air conditioning - Dynamic description Receiver/Dryer - Dynamic description Air conditioning - Recover Air-conditioning condenser - Install Receiver/Dryer - Install Expansion valve - Install

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Contents Cab climate control - 50 Heating - 100

FUNCTIONAL DATA Heating Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Heating Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Cab climate control - Heating

Heating - Dynamic description Fluid from the engine to the heater The fluid exits the engine, from the thermostat housing, through hose (1).

CUIL13TR00787AA

CUIL13TR00740AA

CUIL13TR00787AA

In the cab roof, on the left-hand side of the heater, the hose (1) , figure (1), is connected to the fitting (1).

Fluid from the heater to the engine The hot fluid, after crossing the heater, exits through the copper fitting (2).

The fluid returns through the upper socket in the bottom radiator pipe through the hose (2).

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Cab climate control - Heating

Temperature control The intensity of the heat released to the cab interior is determined by the flow of hot coolant that circulates through the heater (2). The flow control is controlled by the valve (1) located on the left-hand side of the heater.

CUIL13TR00732AA

CUIL13TRO0192AA

Control of the valve (1), figure 5, is through the button (1) and its respective cable.

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Cab climate control - Heating

Heating - Remove 1. Disconnect the negative battery cable from the battery. 2. Apply the parking brake. 3. Drain a few liters of radiator coolant. Consult the procedures in Radiator - Drain fluid (10.400). 4. Remove the bolts around the cover (1). Remove the cover from the cab roof.

CUIL13TR00744AA

CUIL13TR00759AA

CUIL13TR00740AA

5. Remove the two mounting bolts securing the climate controls (1) and remove the climate controls. 6. Release the mounting clip (2) from the control cable. Disconnect the end of the cable from the panel lever. 7. Tag and disconnect the cables (3) from the thermostat. 8. Tag and disconnect the fan control cables (4). 9. Remove the cab liner. Consult the procedures in Cab roof - Remove (90.150).

10. Disconnect the hose (3) from the fitting (1). This is the hose for the flow of hot fluid to the heater. 11. Disconnect the hose (4) from the fitting (2). This is the return hose for fluid from the heater to the engine.

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Cab climate control - Heating

12. Remove the heater assembly (1).

CUIL13TR00732AA

CUIL13TR00764AA

CUIL13TR00738AA

13. Remove the nuts (1) and washers. Remove the control valve (2). 14. Discard the gasket (3). 15. Inspect the heater (4). Perform a leak test under pressure with the heater immersed in water. Check the outer part of the heater for warping, oxidation and other defects. 16. Check for free movement of the control valve control lever (2) . With the lever in the fully closed position, there should be no passage of fluid.

Drain hoses There are two drain hoses around the evaporator box (4) â&#x20AC;˘ Rear hose (3): descends through intermediate lateral pillar of the cab, exiting through the internal part of the fender. â&#x20AC;˘ Front hose (5): descends through front pillar of the cab, exiting through the bottom corner. 1. Check hoses for damage or drying out. Replace the hoses if needed. NOTE: Drain hoses (3) and (5) use clamps with bolt. Heater hoses (1) and (2) use pressure clamps (elastic).

Next operation: Heating - Install (50.100).

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Cab climate control - Heating

Heating - Install Prior operation: Heating - Remove (50.100). 1. Install the drain hoses in their respective fittings. NOTE: Drain hoses (3) and (5) use clamps with bolt.

CUIL13TR00738AA

CUIL13TR00764AA

CUIL13TR00732AA

CUIL13TR00744AA

2. Check that the contact faces of the flanges, control valve (2) and heater (4) are clean. 3. Use a new gasket (3). 4. Install the control valve (2) in the heater (4). Attach the valve with the nuts and washers (1).

5. Position the heater assembly (3) and the control valve (1) inside the evaporator box (2), on the roof. 6. Install a new heat insulation blanket (5) on the control valve (1) and return piping. 7. Ensure correct fitting and routing of the control cable (4).

8. Install the cover (1) on the roof and attach it with mounting bolts.

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Cab climate control - Heating

9. Connect the hose (3) onto the fitting (1). 10. Connect the hose (4) onto the fitting (2). NOTE: Heater hoses (3) and (4) use pressure clamps (elastic). 11. Re-install the cab liner. Consult the procedures in Cab roof - Install (90.150).

CUIL13TR00740AA

CUIL13TR00765AA

CUIL13TR00766AA

CUIL13TR00760AA

12. The end of the cable (1) is attached in the hole (3) of the lever (2), i.e. in the hole at the end.

13. Turn temperature control selector (2) all the way counter-clockwise. 14. Push the end (1) of the cable (3) fully inside. This places the control valve regulator lever in the closed position. 15. With the aforementioned items kept in the specified position, attach the clip (4) on the back face of the control panel.

16. Connect the thermostat and fan control cables (3). NOTE: Refer to Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (55.100) for electrical schematic. 17. Make sure that the clips (1) and (2) are in good condition and correctly fitted on the lining for correct mounting of the control panel.

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Cab climate control - Heating

18. Attach the climate control panel to the roof lining using the bolts. 19. Connect the negative battery cable. 20. Top up the level or replace the engine coolant. NOTE: When starting the engine, turn on the heating system and let the heating system run for 5 minutes on the maximum heat setting. Shut down the engine and top up the level of coolant.

CUIL13TR00761AA

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Index Cab climate control - 50 Heating - 100 Heating - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Heating - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Cab climate control - 50 Ventilation - 104

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Contents Cab climate control - 50 Ventilation - 104

FUNCTIONAL DATA Ventilation Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SERVICE Ventilation Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Air filter Replace - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

(*) See content for specific models 47835583 21/10/2015

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Cab climate control - Ventilation

Ventilation - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

The fan blows air from outside the cab through the inlet filters (1) and forces the air through the evaporator before the air enters the cab through the ventilation grills.

LAIL11TL0091A0A

The fan motor is controlled by a three-speed switch (1). This uses a variable resistance to change the fan speed. A higher fan rotation allows circulation of a greater volume of air, however a slower rotation allows the air to come into more prolonged contact with the fins and coils of the cooler, resulting in the hot air transferring more heat to the refrigerant, which is at a lower temperature. In these conditions, the lowest air temperature is obtained when the fan is working at its lowest speed.

CUIL13TRO0192AA

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Cab climate control - Ventilation

Ventilation - Remove 1. Disconnect the negative (-) cable (1) from the battery. 2. Discharge and recover the refrigerant using an approved recovery system. Consult the procedures in Air conditioning - Recover (50.200).

CUIL13TRO0194AA

CUIL13TR00744AA

CUIL13TR00736AA

CUIL13TR00738AA

3. Remove the bolts around the cover (1). Remove the cover from the cab roof.

4. Remove the electrical connector (1). 5. Remove the heater. Consult the procedures in Heating - Remove (50.100). 6. Remove the air-conditioning evaporator. Consult the procedures in Air-conditioning evaporator - Remove (50.200). 7. Remove cap screws (2).

8. Remove the evaporator box (1) from the housing on the roof.

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Cab climate control - Ventilation

9. To gain access to the electrical connectors for engine power supply, remove the assembly of fans (3) and (5) and the support plate (6). 10. Remove the bolts (1) and (2) and separate the fans (3) and (5) from the plate (6).

CUIL13TR00767AA

Next operation: Ventilation - Install (50.104).

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Cab climate control - Ventilation

Ventilation - Install Prior operation: Ventilation - Remove (50.104). 1. Attach the fans (3) and (5) on the plate (6) with the bolts (1) and (2). 2. Move the fan assembly and the housing plate to the roof. 3. Install the electrical connectors at the wire harness plug coming from the fan control panel. Refer to Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (55.100) for electrical schematic. 4. Position the fans (3) and (5) with the support plate (6) into the housing and secure the assembly with the upper bolts

CUIL13TR00767AA

CUIL13TR00737AA

5. Install the screws (1). 6. Install the heater and drain hoses. Consult the procedures in Heating - Install (50.100). 7. Install the air-conditioning evaporator. Consult the procedures in Air-conditioning evaporator - Install (50.200).

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Cab climate control - Ventilation

Air filter - Replace - Replace Paper filter Perform the following procedure to replace the cab's outer air filter element: 1. Loosen the knobs (1). Remove the guard plate (2).

CUIS15TR00197AA

CUIS15TR00195AA

2. Loosen the knobs (3). Remove the filter (4) . 3. Clean the screen filter and air filter housing. NOTE: The filters are made of specially treated media with a rubber sealing strip bonded to the upper surface. Take care not to damage the element during removal. 4. Install the filter in the reverse order of removal. NOTE: The filter should be installed with the arrow pointing inward. NOTICE: Make sure that the seals are not damaged. If in doubt, replace the seals. 5. Perform steps 1 to 4 on the other side of the cab.

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Index Cab climate control - 50 Ventilation - 104

(*)

Air filter - Replace - Replace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ventilation - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

Cab climate control - 50 Air conditioning - 200

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Contents Cab climate control - 50 Air conditioning - 200

TECHNICAL DATA Air conditioning General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Air-conditioning compressor Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Compressor drive belt General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FUNCTIONAL DATA Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Air-conditioning compressor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Air-conditioning condenser Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Receiver/Dryer Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Expansion valve Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Air-conditioning evaporator Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

SERVICE Air conditioning Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 Exterior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Connect the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 Disconnect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Startup test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

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Recover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Air-conditioning compressor Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Compressor drive belt Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Air-conditioning condenser Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Receiver/Dryer Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Expansion valve Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Air-conditioning evaporator Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

DIAGNOSTIC Air conditioning Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

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CONSUMABLES INDEX Consumable R134a R134a R134a R134a R134a R134a R134a R134a R134a R134a R134a

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Cab climate control - Air conditioning

Air conditioning - General specification TL60E Refrigerant specification Refrigerant charge Low pressure switch on Low pressure switch off High pressure switch on High pressure switch off

TL75E

TL85E R134A 1400 g + 1.8 - 2.5 bar 1.25 - 2.7 bar 19.5 - 22.5 bar 25.5 - 28.5 bar

TL95E

Air conditioning - Special tools Always use approved and suitable equipment for the recovery, recycling, and recharging of the air-conditioning refrigerant of tractors. The special equipment should be purchased from trustworthy suppliers. Contact the supplier for details about the latest equipment available for repairing the air-conditioning system. Acquire Acquire Acquire Acquire Acquire Acquire Acquire Acquire

Portable vacuum/charge system Recovery/recharge Portable system Condenser and evaporator cleaner Tape to expansion valve tool Electronic gas leak detector Gauge set Quick release joint tool Compressor tools

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locally locally locally locally locally locally locally locally

Cab climate control - Air conditioning

Air-conditioning compressor - Torque Compressor assembly bolts

43.0 - 56.0 NÂˇm (31.7 - 41.3 lb ft)

Air-conditioning compressor - General specification TL60E Compressor Number of cylinders Cylinder displacement

TL75E

TL85E Sanden 5 154.9 cmÂł

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TL95E

Cab climate control - Air conditioning

Compressor drive belt - General specification TL60E New belt tension Used belt tension

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TL75E

TL85E 26 - 28 kg 22,5 - 24 kg

TL95E

Cab climate control - Air conditioning

Air conditioning - Dynamic description Air conditioning principles The function of the air conditioning system is to increase the operator's comfort by cooling the air inside the cab and reducing humidity. This temperature control is reached by absorbing heat from inside the cab to a refrigerant and transferring this heat to the outside air. To achieve this heat transfer, the following heat formation and transfer principles apply to the air conditioning system: When two bodies at different temperatures come in contact, heat is transferred from one to the other. In air conditioning systems, an evaporator is used to circulate the refrigerant at a low temperature and absorb the heat from the air inside the cab.

LAIL11TL0930A0A

LAIL11TL0931A0A

LAIL11TL0932A0A

When a gas is pressurised, its temperature increases. In air conditioning systems this is achieved using a compressor.

When a gas is cooled, it condenses. In air conditioning systems, a condenser is used to cool the refrigerant and the resulting liquid is collected into a filter-dryer.

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Cab climate control - Air conditioning

When a liquid is sprayed through a hole, the temperature of the resulting gas will be lower (colder). The atomised liquid's low temperature will absorb the heat from its surroundings. In the air conditioning system, the refrigerant is sprayed using and expansion valve. Therefore, you can see that the main components of an air conditioning system are as follows: • Refrigerant • Evaporator • Compressor • Condenser

LAIL11TL0933A0A

• Filter-drier • Expansion Valve

Air conditioning cycle

LAIL11TL1013G0A

Air conditioning cycle (1) Expansion valve - sprays the refrigerant before it passes to the evaporator. (2) Evaporator - absorbs the cab air heat. (3) Compressor - compresses the refrigerant, increasing its temperature. (4) Condenser - converts the refrigerant into liquid.

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Cab climate control - Air conditioning

Air conditioner refrigerant circulation Low pressure

Expansion Valve ↓ Low temperature and pressure: fluid atomized ↓ Evaporator: Heat from the cab air is transferred to the refrigerant ↓ Refrigerant as vapor and low pressure slightly heated ↓

High pressure High temperature and high pressure of refrigerant as vapor ↑ Condenser: Heat is transferred from the refrigerant to the outside air ↑ Refrigerant with low temperature and high pressure ↑

Filter-drier ↑ Low temperature. High temperature of filtered coolant and humidity removed ↑ Compressor

Refrigerant is drawn into the compressor as cool, low pressure vapor which is compressed and then pumped as hot, high pressure vapor to the condenser. When this hot, high pressure vapor passes through the condenser, it heats up the air around the cooler, which is at a lower temperature and is aspirated by the motor's fan through the radiator's fins. Transferring heat to the outside air, the steam circulating at high pressure condenses and flows to the filter-dryer where it is stored until it is released to the evaporator via the temperature-sensitive expansion valve. When the refrigerant goes through the calibrated orifice in the expansion valve, it changes from a high-pressure liquid to an atomised low-pressure fluid with a low temperature. This low pressure, low temperature, atomised liquid enters the evaporator coil and absorbs the heat from the hot cab air which is blown onto the coil by the fan. The refrigerant then goes from an atomised, cold, low pressure liquid, leaving the evaporator, and moves on to the compressor's suction side (low pressure) to repeat the cycle. As this loss of heat takes place, the humidity in the cab air condenses outside the evaporator. The water is drained through the drain tubes of the air conditioning set, which reduces the humidity level in the cab.

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Cab climate control - Air conditioning

Air conditioning - Dynamic description Refrigerant NOTICE: R134A refrigerant is not compatible with refrigerant R-12 . Do not try to replace HFC134a refrigerant with R-12 or test the system using pressure gauges or equipment previously used with R-12 as this will damage the system. To achieve the absorption and release of heat, which is essentially the function of an air conditioning system, a liquid with a relatively low boiling point temperature must be used in certain desirable safety and stability conditions. The refrigerant used in the air-conditioning system is R134A. To avoid the wrong type of refrigerant being charged into the system, the Schrader service valves installed on the machine and needed for the recovery, drainage and recycling/recharging of the equipment come in two different sizes, approved and specified by the air conditioner manufacturer. R134A refrigerant is stable at all operating temperatures and is capable of absorbing large amounts of heat. The boiling point of R134Ais - 22 °C at atmospheric pressure. If the pressure increases and will quickly evaporate to absorb heat at temperatures from - 11.7 °C to 1.9 bar and 0 °C to 2.9 bar in the evaporator. At higher pressures, the R134A will condense and release heat at temperatures between 48 °C to 12.4 bar and 58 °C to 15.85 bar in the condenser.

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Cab climate control - Air conditioning

Air-conditioning compressor - Dynamic description The machine's air conditioning compressor (1) is located on the right-hand side of the engine. The compressor is driven by a belt (2) connected to the crankshaft pulley. The compressor separates the high and low pressure sides in the system and is basically a pump that carries out two functions: • Increase the refrigerant temperature by compression to above the outside air temperature. • Circulate the required volume of refrigerant through the system. CUIL13TR00333AA

The refrigerant compressor is a unit with an eccentric plate and five cylinders installed in a cast aluminium housing. The eccentric plate is driven by the compressor's pulley by means of an electromagnetic clutch to the main shaft. Connected to this shaft is an eccentric rotor that makes the eccentric plate oscillate. The refrigerant is aspirated during the piston's downward stroke through a valve located on the cylinder's end. The piston's upward travel compresses the refrigerant and expels it through an internal chamber on the cylinder head and then to the refrigerant circuit. The compressor is lubricated with polyalkylene glycol oil (PAG). This oil mixes fully with the refrigerant, passing to the refrigerant's circuit. The compressor is turned on and off by an electromagnetic clutch as required in order to operate the air conditioning. This clutch is engaged primarily by elements: • The temperature cycle control switch • The combined high/low pressure shutoff switch • The low pressure shutoff switch

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Cab climate control - Air conditioning

Air-conditioning condenser - Dynamic description The condenser (1), located at the front of the machine, consists of several continuous turns of a coil mounted on a series of thin fins to ensure maximum heat transfer in the smallest amount of space. The condenser receives the hot, high-pressure refrigerant vapour from the compressor. This hot vapour passes through the condenser coils and the outside air is aspirated through the condenser by the engine cooling fan. The heat moves from the hot refrigerant vapour to the cooler's outside air which circulates through the condenser coils and fins. When the refrigerant vapour reaches the temperature and pressure that will induce a change of state, a large amount of heat is transferred to the outside air and the refrigerant turns into a hot, high pressure liquid. The hot liquid refrigerant passes on to the filter-dryer where it is filtered and dehydrated to eliminate humidity before going on to the outlet tube to the thermostatic expansion valve.

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CUIL13TRO0195AA

Cab climate control - Air conditioning

Receiver/Dryer - Dynamic description The filter-dryer (1) stores the refrigerant to make sure that a constant flow is maintained to the thermostatic expansion valve under various working conditions. The dryer section contains a desiccant (molecular sieve) to absorb any humidity in the system and a filter that keeps foreign particles from getting in. NOTE: Any moisture in the air-conditioning system is extremely disadvantageous. The moisture absorbed in the dehydrator will circulate in the refrigerant and could come together and freeze into drops in the thermostatic expansion valve hole. This will block the flow of R134A refrigerant, forming a corrosive hydrochloric acid. CUIL13TR00712AA

The desiccant can only absorb a limited amount of humidity before reaching the point of saturation. For this reason, after replacing or repairing any component in the system which requires entering the system, the filter-dryer must be replaced.

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Cab climate control - Air conditioning

Expansion valve - Dynamic description The expansion valve (1) is located after the evaporator on the pressure tube that runs from the filter-drier. It performs the following functions: 1. Adjusting action: An adjusting orifice changes the refrigerant flow from a high pressure, high temperature liquid to an atomized low pressure, low temperature liquid. 2. Modulating action: A thermostatically-controlled valve located in the expansion valve body controls the volume of refrigerant that passes through the hole and ensures that the refrigerant is completely vaporized inside the evaporator. The refrigerant would damage the compressor valves or freeze up the pistons. 3. Control action: The valve responds to changes in the cooling needs. When more cooling is needed, the valve opens to increase the refrigerant flow. If the opposite is needed, the valve closes and reduces the refrigerant flow.

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CUIL13TR00737AA

Cab climate control - Air conditioning

Air-conditioning evaporator - Dynamic description The evaporator (1) is located on the cab roof and consists of a certain number of spirals with continuous coils mounted on a series of thin cooling fins which ensure maximum heat transfer in the smallest amount of space. The refrigerant at a low temperature in the evaporator absorbs the heat from the warmer air in the operator's cab and cools it.

CUIL13TR00734AA

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Cab climate control - Air conditioning

Air conditioning - Preliminary test Always run a preliminary troubleshooting diagnosis before beginning to test the system's performance. 1. Set the engine speed between 1000 - 1200 RPM for 10 min with the air conditioner set at maximum cooling and the fan at high speed. 2. Check that the heater temperature control is off. 3. Check that the blower fan is working at all speeds. 4. Check that the compressor's clutch engages when the temperature control switch is moved from off to on. A click indicates that the clutch is engaging. If the clutch does not work, this could mean that there is an electric fault on the high and low pressure shutoff switches or a problem with the compressor's electric clutch action. See your NEW HOLLAND dealer. 5. Check that the engine fan is breathing sufficient cool air via the condenser. 6. Check the compressor belt tension. 7. Check that the protective screen and the condenser grid are clean and unobstructed. 8. Check that the cab air filters are clean and unobstructed. 9. Check that the evaporator fins are not stuck together or are too dirty. 10. If any problem it noted after this test, connect the pressure gauge set on the machine by following the procedures described in Air conditioning - Connect the pressure gauge set (50.200).

Servicing components (except the compressor) 11. If a component needs to be replaced while servicing the system, any refrigerant in the component to be replaced should be drained into a suitable container. 12. A volume of refrigerant equivalent to that drained from the replaced component must be added to the new component before installing it in the machine. 13. After completing the repair, evacuate, recharge and run leak and performance tests on the system to make sure it is operating correctly.

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Cab climate control - Air conditioning

Air conditioning - Exterior washing DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

WARNING Explosion hazard! Air-conditioning refrigerant boils at -12 Â°C (10 Â°F)! -NEVER expose any part of the air-conditioning system to a direct flame or excessive heat. -NEVER disconnect or disassemble any part of the air-conditioning system. Discharging refrigerant gas into the atmosphere is illegal in many countries. Failure to comply could result in death or serious injury. W0340A

WARNING Avoid chemical burns! Wear protective goggles and non-permeable gloves when working with the fluorescent dye and leak testing an air-conditioning system. Failure to comply could result in death or serious injury. W0918A

Washing the air conditioning system The air-conditioning system can occasionally become contaminated with solid particles. This contamination could be the result of foreign matter getting into the system when it is open, such as corroded aluminium or mud, or parts of worn spring plates from the compressor. Contamination of this kind can cause blocked evaporators, condensers and expansion valves. 1. Drain the system following in the procedures described in Air conditioning - Recover (50.200). 2. Contaminated systems must be washed with a special solvent to eliminate unwanted materials. Each individual component should be washed after all of the pipe accessories have been removed. NOTICE: The compressor and expansion valve cannot be washed, so the compressor must be disassembled and cleaned or replaced and the expansion valve must be replaced. NOTICE: Never use any solvent for washing the air conditioning system other than those specially designed for this purpose. Always follow the manufacturer's recommendations on using washing equipment and solvents. 3. Reinstall the components. 4. Apply vacuum to the system following the procedures described in Air conditioning - Apply vacuum (50.200).

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Cab climate control - Air conditioning

Air conditioning - Connect the pressure gauge set DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

WARNING Avoid injury! Avoid breathing air-conditioning refrigerant, lubricant vapor or mist. If accidental system discharge occurs, ventilate the work area before resuming service. Failure to comply could result in death or serious injury. W1000B

If the workshop has a modern automatic suction, evacuation, recycling and filling device, the manometers are already built into the device. The following instructions for performing a functional test of the air conditioning unit apply to the manometer shown in the figure to the side. In principle, a unit test using a suction and filling device with built-in manometers is performed according to the same procedure. NOTICE: It is essential that the manufacturer's operating instructions are read before using such equipment.

LAIL11TL0094A0A

NOTE: In the closed valves, the refrigerant flows along the rod of the valve for the manometers. As a result, after connection of the pressure battery, both manometers indicate the pressure. Never unscrew or open the manual shut-off valve (2) on the pressure side when the system is operating. Always unscrew or open the manual shut-off valve (6) on the suction side to top up the refrigerant level. NOTICE: The manual shut-off valves should always be bolted and closed during the entire test (clockwise, to the end of the track).

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Cab climate control - Air conditioning

To connect the pressure gauge set on the machine, perform the following procedures: NOTE: Before connecting the pressure gauge set, determine the positioning of the connections for the high-pressure gauge (pressure side) and low-pressure gauge (suction side). The connection valve of the pressure side is located on the air-conditioning compressor line for the condenser. 1. The connection valves are closed with a protective cap. Remove the caps (1) and (2) to connect the pressure gauge. CUIL13TR00475AA

CUIL13TR00475AA

2. Connect the high pressure gauge hose (1), figure 1, on the pressure side shut-off valve (1).

3. Connect the low pressure gauge hose (7), figure 1, to the connection valve (1) on the suction side. Check the tightness of all hose connections. NOTE: The high- and low-pressure-side connection valves on the vehicle are spring-loaded valves and open automatically when the pressure test hose is connected. NOTE: A pin of suitable pressure should be inserted in the pressure test tube to trigger this type of valve.

Next operation: Perform the start-up test according to the procedures in Air conditioning - Startup test (50.200)

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Cab climate control - Air conditioning

Air conditioning - Disconnect of the pressure gauge set Prior operation: Air conditioning - Connect the pressure gauge set (50.200) . NOTE: A significant amount of steam from the refrigerant may have condensed into a liquid at the service joint on the compressor's high pressure side. Use a thick cloth or other protective material when disconnecting the manifold tube from that joint to avoid personal injury to the hands or face. 1. Disconnect the connection valves on the low pressure side (1). 2. Disconnect the connection valves on the high pressure side (2).

CUIL13TR00475AA

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Cab climate control - Air conditioning

Air conditioning - Startup test DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Prior operation: Connection of the pressure gauge set. Consult the procedures in Air conditioning - Connect the pressure gauge set (50.200) . The system should be stabilized after connection of the pressure gauge set and before the pressure tests are performed. Carry out the following procedures: 1. Check that the higher pressure valve (2) and low pressure valve (6) on the pressure gauge set are completely closed. 2. Apply the parking brake. 3. Be sure the gear levers are in neutral 4. Close the windows of the cab door. 5. Adjust the engine speed to 1000 - 1200 RPM. 6. Turn off the heater temperature control. 7. Turn on the air conditioning and set to the maximum ventilation and maximum cooling. Continue to run the air conditioning for 10 minutes.

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LAIL11TL0094A0A

Cab climate control - Air conditioning

8. Check that the reading on the low pressure gauge (7) is within the specific values, approximately 0.28 2.48 bar (4.1 - 36 psi). 9. Check the high pressure gauge reading (1) and compare it with that indicated on the pressure and temperature chart in table 01.

LAIL11TL0094A0A

Table 01: Ratio of temperature by pressure High pressure gauge reading 10 - 11.6 bar (145.0 - 168 psi) 11.2 - 12.7 bar (162.4 - 184 psi) 12.3 - 13.8 bar (178.4 - 200 psi) 13.3 - 15.2 bar (192.9 - 220 psi) 14.5 - 16.7 bar (210.2 - 242 psi) 16.0 - 18.3 bar (232.0 - 265 psi) 17.3 - 20 bar (250.9 - 290 psi)

Ambient air temperature 27 °C 29 °C 32 °C 35 °C 38 °C 41 °C 43 °C 10. Measure and compare the temperature of the conditioned air entering the cab through the air vents with the temperature of the ambient air in the filter inlet (1). 11. If the system is working correctly, the air entering the cab should be 6 - 9 °C cooler than the outside ambient air temperature. 12. If it is confirmed that the system is not working properly, refer to the procedures according to the type of problem encountered. See the references in Air conditioning - Troubleshooting (50.200) NOTE: The examples described in Air conditioning Troubleshooting (50.200) show the typical readings for the high- and low-pressure gauges during the air-conditioning system performance test at an ambient temperature of 35 °C (95.0 °F).

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Cab climate control - Air conditioning

Air conditioning - Leakage test DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Use an electronic detector to conduct the leak test if any leaks are detected. Electronic detectors use warning lights or warning sounds to indicate the presence of a leak. If the sensitivity of the detector is adjustable, calibrate it in accordance with the manufacturer's instructions before using it. NOTE: A small leak in the area of the compressor pulley is normal. This does not necessarily mean that any repair is needed.

LAIL11TL0093A0A

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Cab climate control - Air conditioning

When locating a leak, note the following: 1. Discharge the system using a certified recovery machine. Consult the procedures in Air conditioning Recover (50.200). 2. Repair the leak. 3. Evacuate the system. Consult the procedures in Air conditioning - Apply vacuum (50.200). 4. Charge the system with compressed air only. Wait approximately 15 min and check the system's pressure, which should be stable, indicating an absence of leaks. 5. Check for leaks in the system. 6. Discharge the compressed air. 7. Fully charge the system. Consult the procedures in Air conditioning - Charging (50.200). 8. Always run a leak test as the final operation after evacuating a system and then charging it again.

LAIL11TL0939B0A

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Cab climate control - Air conditioning

Air conditioning - Recover DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

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Cab climate control - Air conditioning

There are numerous laws prohibiting the release of refrigerant into the atmosphere. Whenever checking the air-conditioning system or carrying out other tasks that involve disarming the system, the refrigerant must be discharged before starting the operation. Before disassembling the air conditioner for repairs, discharge and recover the refrigerant using a certified recovery machine according to the manufacturer's instructions. The figure to the side shows a combined refrigerant recovery, drainage, and recycling/recharging machine. This equipment removes the R134A refrigerant from the air-conditioning system, recycles it, and does the recharging all in one consecutive operation. This unit was designed to be used with the set of gauges installed in its control panel. There are several other recovery systems on the market that do not include the set of gauges. A separate gauge set must be used when using this type of equipment. Perform the following procedures to discharge the system using a recovery/recharge unit: NOTICE: Never discharge refrigerant into the atmosphere. Always wear safety goggles and gloves when working with these fluids. Use only certified packages. NOTICE: Always follow the manufacturer's instructions when working with recovery equipment.

LAIL11TL0939B0A

CUIL13TR00475AA

1. Turn on the air conditioning system for a few minutes. 2. Adjust the recovery unit as recommended by the manufacturer. Make sure that the red tube (high pressure side) (2) is connected to the high joint and that the blue tube (low pressure side) (1) is connected to its respective joint. NOTE: If you are using a unit with pressure gauges, the low and high pressure sides of the pressure gauge are connected to the low and high pressure sides of the machine's system. The recovery unit tube is then connected to the set's central output. 3. To recover the refrigerant, open the high and low pressure valves of the control panel. If using a pressure gauge set, open the valves of the pressure gauge set. 4. Open the valves labelled "gas" and "liquid" in the refrigerant tank of the recovery unit. 5. Turn on the recovery unit. 6. Operate the recovery unit according to the manufacturer's instructions. NOTE: The compressor will stop automatically when the refrigerant removal is complete.

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Air conditioning - Apply vacuum DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

WARNING Explosion hazard! Air-conditioning refrigerant boils at -12 째C (10 째F)! -NEVER expose any part of the air-conditioning system to a direct flame or excessive heat. -NEVER disconnect or disassemble any part of the air-conditioning system. Discharging refrigerant gas into the atmosphere is illegal in many countries. Failure to comply could result in death or serious injury. W0340A

Prior operation: Air conditioning - Recover (50.200) . NOTICE: A system from which the refrigerant has been recovered to facilitate any repairs must be evacuated before being refilled with new refrigerant. A vacuum pump is used to eliminate the air and moisture from the system. The automatic recycling, recharging and drainage systems, or the draining and charging systems provided by the air conditioning manufacturer, also include a vacuum pump. If this type of equipment is not available, use a vacuum pump and an independent set of gauges. When a system is being evacuated, the boiling point of any moisture is also lowered. When the vacuum increases, the boiling point ends up falling below the ambient temperature and under these conditions the moisture boils and is eliminated. The information in table 01 is the ratio between the system vacuum and the boiling temperature at which water steam is eliminated from the system. Table 01: Ratio between the system vacuum and the boiling temperature Mercury system vacuum 710 mm Hg 734 mm Hg

Engine coolant 38 째C 27 째C 47835583 21/10/2015

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Cab climate control - Air conditioning

Mercury system vacuum 746 mm Hg 754 mm Hg 757 mm Hg 759 mm Hg

Engine coolant 16 째C 5 째C - 7 째C - 18 째C

NOTE: For every 305 m above sea level, 25.4 mm Hg must be added to the vacuum meter reading to compensate for the change in atmospheric pressure. 1. If using a pressure gauge set, connect the low pressure side (1) and the high pressure side (2) of the pressure gauges to the low and high sides of the machine's airconditioning system. NOTICE: Make sure the system is completely discharged as the refrigerant will damage the vacuum pump. 2. Connect the central tube of the pressure gauges to the vacuum pump's inlet port, according to the manufacturer's instructions. 3. Completely open the low and high pressure shut-off valves. 4. If a combined recovery/drainage unit is used, connect it to the air-conditioning system according to the manufacturer's instructions. Read carefully all the instructions before putting the unit in operation.

CUIL13TR00475AA

5. After starting the drainage cycle, check the low gauge to see if a vacuum is forming in the system. 6. Calculate the drainage time as at least 20 min after reaching the lowest vacuum point. 7. When the gauge on the low pressure side reaches the lowest constant vacuum, stop the drainage process. NOTE: The vacuum pump reaches its maximum efficiency when the discharge valve is closed. 8. Check the system by closing the valves, turning off the vacuum pump, and noting the low gauge readout. A loss of more than 5 cm of vacuum in 5 min, means a leak or the presence of humidity in the system. 9. If the gauge pointer remains stopped and the vacuum is maintained for 3 - 5 min, close both the high and low valves, turn and disconnect the central tube of the pump. The system is ready for charging. 10. If a leak is detected, charge the system with around 400 g of refrigerant and identify the leak using a detector. Consult the procedures in Air conditioning Leakage test (50.200). 11. When a leak is detected, discharge and recover the refrigerant, repair the leak and repeat the drainage process. Next operation: Charging the air-conditioning system. Consult the procedures in Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

Air conditioning - Charging DANGER Avoid injury! Observe ALL precautions listed below when servicing the air-conditioning system and handling refrigerant. Failure to comply will result in death or serious injury. D0043A

Prior operation: Apply vacuum to the system. Consult the procedures in Air conditioning - Apply vacuum (50.200).

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1. Check if the charge unit is correctly connected to the machine's air-conditioning system according to manufacturer's instructions. 2. Open the high and low pressure valves on the gauges if a charge unit is going to be used with the gauge set. 3. Charge the system with refrigerant according to the manufacturer's instructions. 4. If the charging process is very slow, close the high pressure side valve and start the engine and the air conditioning so that the compressor can pull the rest of the refrigerant into the system. 5. If the refrigerant charge does not go fully into the air conditioning, recover and recharge it. 6. Close the high- and low-pressure valves on the unit's control panel, or on the pressure gauge set if one is being used, and run a test of the air conditioner as described in Air conditioning - Preliminary test (50.200). 7. After charging a system, use the following start-up procedure to make sure the lubrication oil is adequately spread through the system: â&#x20AC;˘ Check that the air conditioning is off. â&#x20AC;˘ Start the engine and run at idle. â&#x20AC;˘ Turn the air conditioner on and allow the system to run for at least a minute before increasing the engine speed.

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LAIL11TL0939B0A

Cab climate control - Air conditioning

Air-conditioning compressor - Filling The oil level in the air-conditioning compressor must be checked after removing an air conditioning component or if a point of leakage is suspected. Use the following process to check if the correct amount of oil has been added. 1. Start the engine and run at idle. 2. Switch on the air conditioning and let the air-conditioning compressor run for 10 minutes. 3. Remove the refrigerant from the equipment. Consult the procedures in Air conditioning - Recover (50.200). 4. Remove the oil filler plug. 5. Turn the grease plug to allow the oil dipstick (1) to be completely inserted. 6. There is enough oil if 5 to 7 marks have been covered.

1B0O2004061087

BAIL07APH419AVA

7. Top up the oil. See the specification and quantity of fluid in Capacities (). 8. Check that the filler opening and the filler point seal ring are completely clean and free from damage. 9. Re-install the plug. 10. Pull out the dipstick and count how many marks have been covered by the oil. 11. Apply vacuum to the system. Consult the procedures in Air conditioning - Apply vacuum (50.200). 12. Charge the system. Consult the procedures in Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

Air-conditioning compressor - Remove 1. Recover the refrigerant from the air-conditioning system. Consult the procedures in Air conditioning - Recover (50.200). 2. Remove the compressor clutch drive connector. 3. Remove the compressor high and low pressure connections (1) and (2). NOTE: Identify the components to facilitate re-installation.

CUIL13TR00806AA

CUIL13TR00817AA

CUIL13TR00806AA

4. Loosen the bolts (1) and (3).

5. Remove the nut from the lower fastening bolt (3). 6. Move the compressor down to loosen the drive belt. Remove the belt from its pulleys. 7. Remove the lower bolt (3) and remove the compressor from the machine.

Next operation: Air-conditioning compressor - Install (50.200) .

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Cab climate control - Air conditioning

Air-conditioning compressor - Install Prior operation: Air-conditioning compressor - Remove (50.200) . 1. Place the compressor on the support and install the lower bolt (3) and the respective nut in the front part. NOTE: Tighten this bolt only after adjusting the belt tension. NOTE: There is a spacer that should be in front of the support.

CUIL13TR00806AA

CUIL13TR00817AA

CUIL13TR00806AA

2. Install the belt (2) over the pulleys. NOTE: Check the condition of the belt. Replace it if necessary. 3. If removed, reinstall the tensioner. NOTE: Check that the lobe on the upper part of the tensioner is facing forward. 4. Adjust the compressor belt tension. Consult the procedures in Compressor drive belt - Tension adjust (50.200).

5. Tighten the nut from the lower fastening bolt (3) of the compressor. 6. Install compressor fittings (1) and (2). 7. Install the drive connector for the compressor clutch. 8. Apply the vacuum to the system. Consult the procedures in Air conditioning - Apply vacuum (50.200). 9. Charge the system with gas. Consult the procedures in Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

Compressor drive belt - Tension adjust The compressor operating belt tension is particularly important in regards to the operation of the air conditioner system. Special care is therefore needed related to: 1. Proper adjustment of the belt and verification of tension. 2. General condition of the belt. The first time it is adjusted, the belt must not be assembled by force, pulled with a screw driver or rolled over the end of the pulley, since that would stretch the less deformable belt fabric and thus resulting in subsequent rupturing of the other fabrics. The first time it is adjusted, the belt must be installed with a higher tension than normal to compensate for initial lacing during the running in period. The belt must be checked again after 50 hours of operation and adjusted to its normal tension. NOTICE: If the belt is overstretched, it will deteriorate prematurely and will also damage the pulley bearings. On the other hand, if the belt is loose it starts to spin and overheat, and will therefore wear very quickly. Perform the following procedures to adjust the belt tension: 1. Park the machine on a level and hard surface. 2. Turn off the engine of the machine. 3. Check whether the belt has a clearance (A) between 12 - 13 mm with a load of 8 - 10 kg (17.6 - 22 lb), measured at the center of the belt. 4. To adjust the belt slack, loosen the screw (1) and adjust the tightener (2). NOTE: The belt must be replaced if it shows any damage such as cuts or requires frequent adjustment. CUIL13TR00478AA

Next operation: Compressor drive belt - Inspect (50.200) .

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Cab climate control - Air conditioning

Compressor drive belt - Inspect Prior operation: Compressor drive belt - Tension adjust (50.200) . When checking the tension, also check the amount of drive belt wear. The main issues are the following: • Shiny belt: the smooth sides can slip on the pulleys. • Cracked belt: can split suddenly due to the slits on the internal surface caused by excess flexing. • Worn edges: with worn edges or a cracked internal surface, the belt can suddenly split at any moment. • Belt impregnated with grease: the belt will wear more quickly as the grease softens its inner surface Take the following measures: 1. If the belt is very loose, put it under the correct tension. If it is very hot, replace it with a new one. 2. If the crack is deep, extending to half the belt's thickness, replace it with a new one. 3. Clean the belt with a dry, clean cloth. 4. If the belt is making high-pitched noises (squeaking) when operating, check the tension and adjust if necessary. If the noise persists, replace the belt with a new one. 5. If the belt has been overstretched and cannot be put under enough tension, replace it with a new one.

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Cab climate control - Air conditioning

Air-conditioning condenser - Remove 1. Disconnect the negative battery cable. 2. Discharge and recover the refrigerant using a duly approved recovery system. Consult the procedures in Air conditioning - Recover (50.200). 3. Disassemble the condenser gas hoses (3) and (4). NOTE: Protect the disconnected ends with appropriate plugs. 4. Turn the lock (2) counter-clockwise and pull the condenser (1).

CUIL13TRO0206AA

Next operation: Air-conditioning condenser - Install (50.200)

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Cab climate control - Air conditioning

Air-conditioning condenser - Install Prior operation: Air-conditioning condenser - Remove (50.200) Carry out the following procedures: 1. Install the condenser (1) to the support and secure it with the wing nut (2). 2. Install the two hoses (2) and (3) on the condenser. 3. Connect the negative battery cable. 4. Apply vacuum to the system. Consult the procedures in Air conditioning - Apply vacuum (50.200). 5. Charge the system with gas R134A using a duly approved recovery system. Consult the procedures in Air conditioning - Charging (50.200). NOTE: For proper operation and efficiency of the cooling system and the air conditioner, it is important that the radiator fins are kept clear and clean, free of accumulation of dust or straw waste. 6. For cleaning, apply a jet of water or compressed air from the back to the front through each core of the radiator and the condenser. NOTICE: The pressure should be up to 7.0 bar (101.5 psi). Excessive pressure can damage the radiator plates. 7. Use a solution with detergent to remove oily substances stuck to the radiators. Straighten the radiator cores if they are crooked.

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CUIL13TRO0206AA

Cab climate control - Air conditioning

Receiver/Dryer - Remove Carry out the following procedures: 1. Disconnect the negative battery cable. 2. Discharge and recover the refrigerant using a duly approved recovery system. Consult the procedures in Air conditioning - Recover (50.200). 3. Disconnect the electrical connection element (2) from the filter-dryer

LAIL11TL0088A0A

CUIL13TR00763AA

4. Disassemble the hose (1) that connects the filter-drier to the evaporator (on the cab roof) 5. Disassemble the hose (2) that connects the filter-dryer (4) to the condenser (5). NOTE: Protect the ends of the hoses (1) and (2) against the entry of dirt into the system. 6. Remove the bolt that fastens the clamp (3) and remove the filter-dryer.

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Cab climate control - Air conditioning

Receiver/Dryer - Install Carry out the following procedures: 1. Install the filter-drier (4) on the clamp (3) and tighten the respective bolt. NOTE: The pressure sensor should be facing forward. 2. Remove the guard and install the hose (2) that connects the filter-drier (4) to the condenser (5). 3. Remove the guard and install the hose (1) that connects the filter-drier (4) to the evaporator (on the cab roof). 4. Disconnect the electrical connection element (2) from the pressure sensor. 5. Apply vacuum to the system. Consult the procedures in Air conditioning - Apply vacuum (50.200). 6. Charge the system with gas R134A using a duly approved recovery system. Consult the procedures in Air conditioning - Charging (50.200). 7. Reconnect the negative battery lead.

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CUIL13TR00763AA

Cab climate control - Air conditioning

Expansion valve - Remove 1. Disconnect the negative (-) battery cable from the battery. 2. Apply the parking brake. 3. Discharge and recover the refrigerant using an approved recovery system. Consult the procedures in Air conditioning - Recover (50.200). 4. Remove the bolts around the cover (1) and remove the cover from the cab roof.

CUIL13TR00744AA

CUIL13TR00775AA

CUIL13TR00736AA

CUIL13TR00731AA

5. Remove the two self-locking nuts (1) and (2) and remove the retaining plate (3).

6. Move the pressure (1) and return hoses (2) away.

7. Discard the seal rings (1) and (2). 8. Remove the studs (6). NOTICE: Be careful not to damage evaporator tubes. 9. Separate the expansion valve assembly (5) from pipes (3) and (4).

Next operation: Expansion valve - Install (50.200) 47835583 21/10/2015

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Cab climate control - Air conditioning

Expansion valve - Install Prior operation: Expansion valve - Remove (50.200) 1. Install a new expansion valve (3). 2. Attach the expansion valve (3) on the evaporator tubes (5), securing it with the studs (1). NOTE: Use new seals (2) and (4). Be careful not to force the evaporator tubes.

CUIL13TR00769AA

CUIL13TR00736AA

CUIL13TR00731AA

CUIL13TR00775AA

3. Condition the pressure (2) and return hoses (1) so that they are not kinked or forcing the connection terminals onto the expansion valve .

4. Install new seal rings (1) and (3) in the expansion valve (2).

5. Install the retaining plate (32) and secure it with the self-locking nuts (1) and (2). NOTICE: Make sure that the hoses are not kinked inside the cab roof. If necessary, pull the hoses through the base of the cab, on the right-hand side. 6. Apply a vacuum to the gas circuit and recharge with R134A gas. Use an approved recovery system. Consult the procedures in Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

7. Install the cover (1) and secure it with four bolts. 8. Connect the negative battery cable. 9. Start the engine and turn on the air-conditioning system, checking the operation of the system.

CUIL13TR00744AA

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Cab climate control - Air conditioning

Air-conditioning evaporator - Inspect 1. Disconnect the negative battery cable from the battery. 2. Apply the parking brake. 3. Drain and recover the refrigerant using approved recovery systems. Consult the procedures in Air conditioning - Recover (50.200). 4. Remove the bolts around the cover (1). Remove the cover from the cab roof.

CUIL13TR00744AA

CUIL13TR00737AA

5. Perform a visual inspection of the evaporator (1) for oxidation, bent fins, and other damage. Straighten the evaporator fins if necessary. 6. Clean the evaporator thoroughly, making sure there are no other obstructions. 7. If the evaporator is in poor condition, with oxidation or a suspected refrigerant leak, remove it from the housing. Consult the procedures in Air-conditioning evaporator - Remove (50.200). 8. If there is refrigerant leakage, replace the evaporator.

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Cab climate control - Air conditioning

Air-conditioning evaporator - Remove NOTE: You do not need to disconnect refrigerant circuit hoses to separate the tractor between the front axle and engine or between the engine and transmission. Loosen the compressor (1), the condenser (2) and the filter-drier (3) from their respective supports and take them into the cab, keeping the hoses and fittings connected. To remove the air-conditioning evaporator, carry out the following procedures:

CUIL13TR00712AA

CUIL13TR00744AA

CUIL13TR00775AA

CUIL13TR00736AA

1. Disconnect the negative battery cable. 2. Discharge and recover the refrigerant using an approved recovery system. Consult the procedures in Air conditioning - Recover (50.200). 3. Remove the bolts around the cover (1). Remove the cover from the cab roof.

4. Remove the two self-locking nuts (1) and (2) and remove the retaining plate (3).

5. Disconnect the return (1) and pressure (2) hoses. NOTE: If you need to remove the hoses (1) and (2) from the cab, remove the inner lining of the roof. Consult the procedures in Cab roof - Remove (90.150).

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Cab climate control - Air conditioning

6. Remove the seal rings (1) and (2) from the expansion valve ports (5). 7. Disconnect the connector (3) from the thermostat.

CUIL13TR00731AA

CUIL13TR00768AA

8. Remove the bolt (5) and loosen the sensor from the clip (3) between the evaporator fins (2). 9. Remove the thermostat (4) and its sensor. 10. Remove the evaporator assembly (2) and expansion valve inside the box (6).

Next operation: Air-conditioning evaporator - Install (50.200).

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Cab climate control - Air conditioning

Air-conditioning evaporator - Install Prior operation: Air-conditioning evaporator - Remove (50.200). 1. Clean the components before installation. 2. Attach the sensor (4) with the bolt (5) and insert the sensor in the evaporator fins (2) by attaching it with the clip (3). NOTE: The thermostat sensor must be carefully reinstalled in its original position. 3. Make sure the seals (1) are positioned and seated properly.

CUIL13TR00768AA

CUIL13TR00731AA

CUIL13TR00736AA

CUIL13TR00775AA

4. Insert the evaporator assembly (4) and the expansion valve (5) in the box (3). 5. Assemble the sealing rings (1) and (2) in the expansion valve ports.

6. Condition the pressure (2) and return hoses (1) so that they are not kinked or forcing the connection terminals onto the expansion valve (7). 7. Fit the hose terminals (1) and (2) in their respective expansion valve ports.

8. Install the retaining plate (3) and secure it with the selflocking nuts (1) and (2). NOTICE: Make sure that the hoses are not kinked inside the cab roof. If necessary, pull the hoses through the base of the cab, on the right-hand side. 9. Connect the thermostat cable (3). 10. Apply a vacuum to the gas circuit and recharge with R134A gas. Use an approved recovery system. Consult the procedures in Air conditioning - Charging (50.200).

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Cab climate control - Air conditioning

11. Install the cover (1) and secure it with the bolts. 12. Connect the negative battery cable. 13. Start the engine and turn on the air-conditioning system, checking the operation of the system.

CUIL13TR00744AA

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Cab climate control - Air conditioning

Air conditioning - Troubleshooting Problem Possible Cause Correction Compressor turns on or Faulty temperature control (thermostat) • Stop the engine and shut off air switch. conditioning system. off very quickly. Gauge reading:• Replace the thermostatic switch with Low Pressure - Very high another of the same type. during on and off cycles • The switch temperature sensor should of the compressor and be installed in the same position and between cycles. depth (in the evaporator's core) as High Pressure - Normal before.

Evaporator air not cool Gauge reading:Low Pressure - Low High Pressure - Low

Refrigerant charge is low.

• Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). • Leak test the system. Consult the procedures in Air conditioning Leakage test (50.200). • Repair leaks. • Check the compressor oil. Consult the procedures in Air-conditioning compressor - Filling (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200).

Insufficient or no cooling Quantity of refrigerant gas extremely low Gauge reading:Low Pressure - Low High Pressure - Low

• Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). • Leak test the system. Consult the procedures in Air conditioning Leakage test (50.200). • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Repair leaks. • Check the compressor oil. Consult the procedures in Air-conditioning compressor - Filling (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200). • Performance test the system. Consult the procedures in Air conditioning Startup test (50.200).

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Problem Possible Cause Insufficient or no cooling Air in system Gauge reading:Low Pressure - Constant when connecting the compressor High Pressure Not constant when connecting the compressor

Correction • Perform system leak test, paying special attention to lines near the compressor. Consult the procedures in Air conditioning - Leakage test (50.200). • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Repair leaks. • Replace the filter-drier. See the procedures in Receiver/Dryer Remove (50.200) and Receiver/Dryer - Install (50.200). • Check the compressor oil. Consult the procedures in Air-conditioning compressor - Filling (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200).

Insufficient cooling Gauge reading:Low Pressure - High High Pressure - Low

Compressor malfunctioning.

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• Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). Replace the compressor. See your NEW HOLLAND dealer.

Cab climate control - Air conditioning

Problem Possible Cause Insufficient or no cooling. Inadequate condenser operation. Engine overheats in some cases. Gauge reading:Low Pressure - Constant when connecting the compressor High Pressure Not constant when connecting the compressor

Correction • Check the belt. Loose or worn drive chains may cause excessive pressures in the compressor poppet. • Look for clogged passages between the serpentine and the condenser fins or other obstructions that could reduce air flow. • If the engine is overheated, replace the engine thermostat and the radiator pressure cap. • Run the system and assess performance. If still unsatisfactory, perform the following procedures: • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Remove the condenser. Consult the procedures in Air-conditioning condenser - Remove (50.200). Fully clean the condenser to ensure unimpeded flow of the refrigerant. Replace the condenser if it is very dirty or blocked. • Replace the filter-drier. See the procedures in Receiver/Dryer Remove (50.200) and Receiver/Dryer - Install (50.200). • Check the compressor oil. Consult the procedures in Air-conditioning compressor - Filling (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200).

Insufficient or no cooling Large amount of air in system. Gauge reading:Low Pressure - High High Pressure - High

• Charge the system. Consult the procedures in Air conditioning Charging (50.200). • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Replace the filter-drier. See the procedures in Receiver/Dryer Remove (50.200) and Receiver/Dryer - Install (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200). • Performance test the system. Consult the procedures in Air conditioning Startup test (50.200).

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Problem Possible Cause Correction Insufficient or no cooling Poor operation of thermostatic expansion Operate the system at maximum cooling. valve (stuck open). Check the low side pressure gauge. The Gauge reading:pressure should drop slowly. If the test Low Pressure - High indicates a defect in the expansion valve, High Pressure - High perform the following procedures: • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Replace the expansion valve. Consult the procedures in Expansion valve Remove (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200).

Insufficient cooling Gauge reading:Low Pressure - Low High Pressure - Low

• Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). Poor operation of thermostatic expansion Operate the system at maximum cooling. valve (stuck closed). Check the low side pressure gauge. The pressure should drop slowly. If the test indicates a defect in the expansion valve, perform the following procedures: • Discharge and recover the refrigerant from the system. Consult the procedures in Air conditioning - Recover (50.200). • Replace the expansion valve. Consult the procedures in Expansion valve Remove (50.200). • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200).

Insufficient cooling Gauge reading:Low Pressure - Low High Pressure - Low. A normal or high pressure gauge reading on the high pressure side in these conditions indicates that either the system is overcharged or the condenser or the accumulator/filter-drier is too small.

• Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). Restriction on the high pressure side of the • Discharge and recover the refrigerant from the system. Consult the procedures system. in Air conditioning - Recover (50.200). • Replace the refrigerant lines, the accumulator/filter-drier or other blocked components. • Apply vacuum to the system. Consult the procedures in Air conditioning Apply vacuum (50.200). • Charge the system. Consult the procedures in Air conditioning Charging (50.200). • Performance test the system. Consult the procedures in Air conditioning Startup test (50.200). 47835583 21/10/2015

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Index Cab climate control - 50 Air conditioning - 200 Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Apply vacuum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Connect the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Disconnect of the pressure gauge set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Exterior washing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Leakage test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Preliminary test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Recover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Special tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Startup test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air conditioning - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Filling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning compressor - Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning condenser - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning condenser - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning condenser - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Air-conditioning evaporator - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor drive belt - General specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor drive belt - Inspect . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Compressor drive belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion valve - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Expansion valve - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Expansion valve - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiver/Dryer - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiver/Dryer - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Receiver/Dryer - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Electrical systems TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

47835583 21/10/2015

Contents Electrical systems - 55

[55.100] Harnesses and connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.1 [55.201] Engine starting system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.2 [55.301] Alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.3 [55.302] Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.4 [55.011] Fuel tank system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.5 [55.014] Engine intake and exhaust system. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.6 [55.012] Engine cooling system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.7 [55.013] Engine oil system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.8 [55.030] Service brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.9 [55.031] Parking brake electrical system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55.10

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Contents Electrical systems - 55 Harnesses and connectors - 100

FUNCTIONAL DATA Wiring harnesses Electrical schema index - Model with cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Electrical schematic sheet 02 SH02 - DIAGRAM LEGEND (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical schematic sheet 03 SH03 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical schematic sheet 04 SH04 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Electrical schematic sheet 05 SH05 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Wiring harnesses - Electrical schematic sheet 06 SH06 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Electrical schematic sheet 07 SH07 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Electrical schematic sheet 08 SH08 - GROUND (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 Electrical schematic sheet 09 SH09 - ENGINE COMPONENTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Electrical schematic sheet 10 SH10 - ENGINE COMPONENTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Electrical schematic sheet 11 SH11 - TRANSMISSION COMPONENTS (*) . . . . . . . . . . . . . . . . . . . . . . . 24 Electrical schematic sheet 12 SH12 - TRANSMISSION COMPONENTS (*) . . . . . . . . . . . . . . . . . . . . . . . 26 Electrical schematic sheet 13 SH13 - INTERIOR LAMPS / BEACON / RADIO (*) . . . . . . . . . . . . . . . . . . 28 Electrical schematic sheet 14 SH14 - WORKLAMPS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Electrical schematic sheet 15 SH15 - LIGHTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Electrical schematic sheet 16 SH16 - SWITCHS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Electrical schematic sheet 17 SH17 - INSTRUMENT CLUSTER (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Electrical schema index - Model without cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (*) . . 42 Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (*) . . . . . . . . . . . . . . 44 Electrical schema Main wire harness of the header – Splices – Sheet 03 (*) . . . . . . . . . . . . . . . . . . . . . . . 46 Electrical schema Main wire harness of the header – Switches – Sheet 04 (*) . . . . . . . . . . . . . . . . . . . . . 48 Electrical schema – Sheet 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50 Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (*) . . . . . . . . . . . . . . . . . . . 52 - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (*) . . . . . 54 Electrical schema – Engine components – Sheet 08 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Electrical schema – Roof lights – Sheet 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Electrical schema – Transmission components – Sheet 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60 Electrical schema – Trailer components – Sheet 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

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Electrical schema – instrument panel – Sheet 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Electrical schema – Ground points – Sheet 13 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Wire connectors Electrical schema index - Model with cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Component diagram 06 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Component diagram 08 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100 Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107 Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109 Component diagram 13 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114 Electrical schema index - Model without cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116 Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132 Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144 Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149 Component diagram 06 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157 Component diagram 08 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164 Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Electrical components ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171 Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172 Diode description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173 Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174 Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175 Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

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Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179 Load description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180 Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181 Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182 Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183 Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema index - Model with cab TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

• Wiring harnesses - Electrical schematic sheet 02 SH02 - DIAGRAM LEGEND (55.100). • Wiring harnesses - Electrical schematic sheet 03 SH03 - FUSEBOX (55.100). • Wiring harnesses - Electrical schematic sheet 04 SH04 - FUSEBOX (55.100). • Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSEBOX (55.100). • Wiring harnesses - Electrical schematic sheet 06 SH06 - FUSEBOX (55.100). • Wiring harnesses - Electrical schematic sheet 07 SH07 - FUSEBOX (55.100). • Wiring harnesses - Electrical schematic sheet 08 SH08 - GROUND (55.100). • Wiring harnesses - Electrical schematic sheet 09 SH09 - ENGINE COMPONENTS (55.100). • Wiring harnesses - Electrical schematic sheet 10 SH10 - ENGINE COMPONENTS (55.100). • Wiring harnesses - Electrical schematic sheet 11 SH11 - TRANSMISSION COMPONENTS (55.100). • Wiring harnesses - Electrical schematic sheet 12 SH12 - TRANSMISSION COMPONENTS (55.100). • Wiring harnesses - Electrical schematic sheet 13 SH13 - INTERIOR LAMPS / BEACON / RADIO (55.100). • Wiring harnesses - Electrical schematic sheet 13 SH13 - INTERIOR LAMPS / BEACON / RADIO (55.100). • Wiring harnesses - Electrical schematic sheet 15 SH15 - LIGHTS (55.100). • Wiring harnesses - Electrical schematic sheet 16 SH16 - SWITCHS (55.100). • Wiring harnesses - Electrical schematic sheet 17 SH17 - INSTRUMENT CLUSTER (55.100). • Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (55.100).

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 02 SH02 - DIAGRAM LEGEND TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

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Electrical systems - Harnesses and connectors

SHT_2

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 03 SH03 - FUSEBOX TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Connector

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Component X-084

LA LA LA LA LA LA

Description

Connector / Link X-084

STARTER SWITCH

Electrical systems - Harnesses and connectors

SHT_3

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 04 SH04 - FUSEBOX TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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LA LA LA LA LA LA

Electrical systems - Harnesses and connectors

SHT_4

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSEBOX TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Connector

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Component X-022

Connector / Link X-022

LA LA LA LA LA LA

Description WORK LAMPS SWITCH LAMP

Electrical systems - Harnesses and connectors

SHT_5

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 06 SH06 - FUSEBOX TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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LA LA LA LA LA LA

Electrical systems - Harnesses and connectors

SHT_6

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 07 SH07 - FUSEBOX TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Diode Connector Connector

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Component D-001 X-045 X-090

Connector / Link X-045 X-045 X-090

LA LA LA LA LA LA

Description DIODE DIODE CORNER LIGHTS SWITCH

Electrical systems - Harnesses and connectors

SHT_7

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 08 SH08 - GROUND TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Ground Ground Ground Ground Ground Ground

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Component GND-001 GND-003 GND-004 GND-006 GND-007 GND-008

Connector / Link GND-001 GND-003 GND-004 GND-006 GND-007 GND-008

LA LA LA LA LA LA

Description GROUND CAB EARTH SWITCHS ILLUMINATION ROOF GND 1 ROOF GND 2

Electrical systems - Harnesses and connectors

SHT_8

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 09 SH09 - ENGINE COMPONENTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Sensor Ground Ground Load Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Solenoid Solenoid

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Component B-001 GND-002 GND-004 L-001 S-001 S-002 S-003 S-014 S-016 SW-010 X-009 X-009A X-010F X-010M X-011 X-012 X-013 X-014 X-060 X-060A X-093 X-093A X-100 X-100A X-126 X-127 Y-001 Y-002

Connector / Link X-011 GND-002 GND-004 X-127 X-009 X-009A X-014 X-093 X-093A X-060 X-060A X-100 X-100A X-126 X-009 X-009A X-010F X-010M X-011 X-012 X-013 X-014 X-060 X-060A X-093 X-093A X-100 X-100A X-126 X-127 X-012 X-013

LA LA LA LA LA LA

Description WATER TEMPERATURE SENDER ENGINE GROUND A/C COMPRESSOR AIR FILTER CLOGGING ENGINE OIL PRESSURE SWITCH BRAKE LIGHT SWITCH RH (NO) BRAKE OIL LEVEL SWITCH BRAKE LIGHT SWITCH LH (NO) A/C PRESSURE SWITCH AIR FILTER CLOGGING AIR FILTER CLOGGING TO ENGINE HARNESS ENGINE CONNECTOR WATER TEMPERATURE SENDER THERMOSTARTER FUEL SHUTT-OFF SOLENOID ENGINE OIL PRESSURE SWITCH BRAKE OIL LEVEL SWITCH BRAKE OIL LEVEL SWITCH BRAKE LIGHT SW RH BRAKE LIGHT SW RH BRAKE LIGHT SW LH BRAKE LIGHT SW LH AIR CONDITIONER PRESSURE SWITCH AIR CONDITIONER CLUTCH THERMOSTARTER FUEL SHUT-OFF SOLENOID

Electrical systems - Harnesses and connectors

SHT_9

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 10 SH10 - ENGINE COMPONENTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Fuse Voltage source Voltage source Ground Ground Speaker Motor Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component F-020 G-001 G-002 GND-001 GND-003 H-001 M-001 X-001 X-002 X-003 X-004 X-010F X-010M X-017 X-053 X-068 X-091 X-098 X-124A X-124B

Connector / Link X-098 X-002 X-053 X-091 GND-001 GND-003 X-124A X-124B X-001 X-001 X-002 X-003 X-004 X-010F X-010M X-017 X-053 X-068 X-091 X-098 X-124A X-124B

LA LA LA LA LA LA

Description MAIN FUSE BATERIA (20) ALTERNATOR GROUND CAB EARTH HORN STARTER MOTOR STARTER MOTOR SOLENOID ALTERNATOR B+ STARTER MOTOR HEATER TO ENGINE HARNESS ENGINE CONNECTOR FRONT HEADLAMPS CONNECTION ALTERNATOR D+ TO ENGINE HARNESS ALTERNADOR W FUSE HORN HORN

Electrical systems - Harnesses and connectors

SHT_10

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 11 SH11 - TRANSMISSION COMPONENTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Diode Switch Connector Connector Connector Connector Connector Connector Connector Solenoid

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Component D-004 S-010 X-005 X-006 X-007 X-097F X-097M X-112A X-112B Y-003

Connector / Link X-112B X-112A X-005 X-006 X-007 X-097F X-097M X-112A X-112B X-005

LA LA LA LA LA LA

Description 4WD DIODE 4WD PRESSURE SWITCH 4WD SOLENOID VALVE 4WD DIODE PTO CLUTCH SWITCH TRANSMISSION HARNESS INTERFACE MAIN HARNESS CONNECTION 4WD PRESSURE SWITCH 4WD PRESSURE SWITCH 4WD SOLENOID VALVE

Electrical systems - Harnesses and connectors

SHT_11

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 12 SH12 - TRANSMISSION COMPONENTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Sensor Lamp Speaker Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component B-004 E-008 H-002 S-006 S-023 X-058 X-097F X-097M X-105A X-105B X-106 X-107 X-108 X-109 X-110 X-111 X-114 X-128 X-129 X-130 X-132 X-177

Connector / Link X-177 X-132 X-105B X-105A X-058 X-058 X-097F X-097M X-105A X-105B X-106 X-107 X-108 X-109 X-110 X-111 X-114 X-128 X-129 X-130 X-132 X-177

LA LA LA LA LA LA

Description FUEL LEVEL SENDER REVERSE LAMP REVERSE ALARM DIFF. LOCK SWITCH HANDBRAKE SWITCH TRANSMISSION HARNESS INTERFACE MAIN HARNESS CONNECTION REVERSE ALARM 1 REVERSE ALARM 2

REVERSE SWITCH 12X12 REVERSE SWITCH 12X4 REVERSE LAMP FUEL LEVEL SENDER

Electrical systems - Harnesses and connectors

SHT_12

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 13 SH13 - INTERIOR LAMPS / BEACON / RADIO TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Ground Ground Load Load Lamp Lamp Lamp Switch Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component GND-010 GND-012 L-009 L-010 LMP-001 LMP-010 LMP-027 S-020 S-021 SW-001 SW-003 SW-015 SW-016 SW-044A001 X-008F X-008M X-024 X-025 X-032 X-049 X-051 X-052 X-066 X-067 X-075 X-076 X-085 X-086 X-094 X-095 X-096 X-101 X-102 X-103

Connector / Link GND-010 GND-012 X-052 X-051 X-067 X-066

X-075 X-076 X-086 X-085

X-032 X-049 X-008F X-008M X-024 X-025 X-032 X-049 X-051 X-052 X-066 X-067 X-075 X-076 X-085 X-086 X-094 X-095 X-096 X-101 X-102 X-103

LA LA LA LA LA LA

Description

SPEAKER RH SPEAKER LH LH CORTESY LAMP RH CORTESY LAMP BEACON LAMP LH INTERIOR LAMP SWITCH RH INTERIOR LAMP SWITCH DOOR SWITCH TURN ON SWITCH DOOR SWITCH TURN ON SWITCH BEACON SWITCH ROOF HARNESS INTERFACE ROOF HARNESS CONNECTORS RADIO (SPEAKERS) RADIO (POWER) BEACON SWITCH BEACON SWITCH LAMP RH SPEAKER REAR SPEAKER LH SPEAKER LH SPEAKER BEACON LAMP BEACON LAMP RH INTERIOR LAMP SUIT LH DOOR SWITCH

Electrical systems - Harnesses and connectors

SHT_13

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 14 SH14 - WORKLAMPS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type ECU Lamp Lamp Lamp Lamp Connector Connector Connector Connector Connector Connector Connector Connector

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Component A-021 LMP-021 LMP-022 LMP-023 LMP-025 X-008F X-008M X-020 X-022 X-079 X-080 X-081 X-082

Connector / Link X-020 X-022 X-082 X-079 X-080 X-081 X-008F X-008M X-020 X-022 X-079 X-080 X-081 X-082

LA LA LA LA LA LA

Description WORKLAMP SWITCH LH FRONT WORKLAMP RH REAR WORKLAMP LH REAR WORKLAMP RH FRONT WORKLAMP ROOF HARNESS INTERFACE ROOF HARNESS CONNECTORS WORK LAMPS SWITCH WORK LAMPS SWITCH LAMP RH REAR WORKLAMP LH REAR WORKLAMP RH FRONT WORKLAMP LH FRONT WORKLAMP

Electrical systems - Harnesses and connectors

SHT_14

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 15 SH15 - LIGHTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Lamp Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component E-001 E-002 E-005 E-006 E-009 E-012 E-015 E-017 E-028 X-015 X-016 X-018 X-019 X-048 X-061 X-069 X-070 X-071 X-072 X-073 X-074 X-078

Connector / Link

X-015 X-016 X-018 X-019 X-048 X-061 X-069 X-070 X-071 X-072 X-073 X-074 X-078

LA LA LA LA LA LA

Description DIP/HIGH BEAM RH DIP/HIGH BEAM LH HOOD WORKLAMP RH HOOD WORKLAMP LH REAR LAMP LH REAR LAMP RH FRONT SIGNAL RH FRONT SIGNAL LH LICENSE PLATE LAMP RH INTERIOR LAMP RH HEADLAMP LH FRONT HOOD WORKLAMP RH FRONT HOOD WORKLAMP LICENSE PLATE RH REAR LAMPS INDICATOR LAMPS - GND RH INDICATOR LAMPS - TURN RH INDICATOR LAMPS - SIDE INDICATOR LAMPS-GND LH INDICATOR LAMPS- TURN LH INDICATOR LAMPS-SIDE

Electrical systems - Harnesses and connectors

SHT_15

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 16 SH16 - SWITCHS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type ECU Relay Switch Switch Switch Switch Switch Switch Switch Switch Switch Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component A-005 K-004 S-004 S-005 S-007 S-008 S-009 S-011 S-013 SW-002 SW-013 X-029 X-031 X-044 X-050 X-056 X-056A X-062 X-063 X-084 X-090 X-092

Connector / Link X-063 X-062 X-050

X-084 X-056A X-090 X-092 X-029 X-031 X-044 X-050 X-056 X-056A X-062 X-063 X-084 X-090 X-092

LA LA LA LA LA LA

Description 4WD SW FLASHER UNIT LIGHTS SWITCH SWITCH SWITCH SWITCH SWITCH STARTER SWITCH THERMOSTARTER SWITCH CORNER LIGHTS SWITCH HAZARD SWITCH (57) LIGHTS SWITCH CLUTCH SWITCH FLASHER UNIT THERMO STARTER SWITCH 2 THERMO STARTER SWITCH 1 4WD SWITCH 4WD SWITCH LAMP STARTER SWITCH CORNER LIGHTS SWITCH CORNER LIGHTS SWITCH LAMP

Electrical systems - Harnesses and connectors

SHT_16

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 17 SH17 - INSTRUMENT CLUSTER TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type Connector

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Component X-054

Connector / Link X-054

LA LA LA LA LA LA

Description INSTRUMENT CLUSTER

Electrical systems - Harnesses and connectors

SHT_17

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

Type ECU ECU Ground Motor Motor Motor Connector Connector Connector Connector Connector Connector Connector Connector Connector Connector

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Component A-001 A-024 GND-005 M-003 M-004 M-005 X-008F X-008M X-021 X-023 X-028 X-057 X-119 X-120 X-121 X-122

Connector / Link X-121 X-122 GND-005 X-119 X-120 X-028 X-008F X-008M X-021 X-023 X-028 X-057 X-119 X-120 X-121 X-122

LA LA LA LA LA LA

Description REAR WASHER SWITCH FRONT WIPER/ WASHER SWITCH FRONT WASHER REAR WASHER REAR WIPER MOTOR ROOF HARNESS INTERFACE ROOF HARNESS CONNECTORS HEATER FRONT WIPER REAR WIPER FRONT WASHER REAR WASHER REAR WASHER SWITCH REAR WASHER SWITCH LAMP

Electrical systems - Harnesses and connectors

SHT_18

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema index - Model without cab TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

• Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100). • Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100). • Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100). • Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100). • Wiring harnesses - Electrical schema – Sheet 05 (55.100). • Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100). • Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) • Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100). • Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100). • Wiring harnesses - Electrical schema – Transmission components – Sheet 10 (55.100). • Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (55.100). • Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (55.100). • Wiring harnesses - Electrical schema – Ground points – Sheet 13 (55.100).

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA ---

Sheet 01 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22)

Component Maxi fuse 1 – 40 A Maxi fuse 2 – 40 A Fuse 3 – 5 A Fuse 4 – 5 A Fuse 7 – 15 A Fuse 8 – 15 A Fuse 9 / Sidelights – 15 A Fuse 10 – 15 A Fuse 11 – 10 A Battery – 100 A·h Fuse 12 – 10 A Fuse 13 – 5 A Fuse 15 – 10 A Fuse 16 – 10 A Fuse 17 – 10 A Fuse 18 – 5 A Fuse 19 – 10 A Fuse 20 – 15 A Fuse 21 – 10 A Fuse 22 – 15 A Fuse 23 – 5 A Fuse 24 – 15 A

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Connector X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022 X-022

Electrical systems - Harnesses and connectors

CUIL13TR00559AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 02 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11)

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Component Relay V – Low beam Power Take-Off (PTO) Relay - F Power Take-Off (PTO) Relay - G Indicator unit – VI Relay A – Sidelights Relay VIII – Brake light Relay IX – Brake light Relay VII – Auxiliary Front Wheel Drive (FWD) Relay E – Reverse alarm Start-up relay - 70 A - I High beam relay – III

Connector K-005 K-017 K-018 K-006 K-019 K-008 K-009 K-009 K-016 K-001 K-003

Electrical systems - Harnesses and connectors

CUVE14TR00186HA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

Sheet 03 Reference (1)

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Component Relay compartment 1 – Ground bar

Connector X-112

Electrical systems - Harnesses and connectors

CUIL13TR00561AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 04 Reference (1) (2) (3) (4) (5) (6) (7)

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Component Power Take-Off (PTO) switch Power take-off switch Park brake switch Header main fuse – 60 A Switch for the brake lights – Left-hand side Switch for the brake lights – Right-hand side Switch for the brake oil level

Connector X-085, X-086, X-087 X-058, X-059 X-038 X-064, X-065 X-062, X-063 X-060, X-061

Electrical systems - Harnesses and connectors

CUIL13TR00562AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema â&#x20AC;&#x201C; Sheet 05 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

Sheet 05 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10)

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Component Connector for the lights Kisa far/Low beam High beam High beam flash Horn Direction switch Start-up connector Cold start connector Warning connector Safe start-up connector

Connector X-031 X-031 X-031 X-031 X-031 X-033 X-057, X-044 X-032, X-034 X-066

Electrical systems - Harnesses and connectors

CUIL13TR00563AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

Sheet 06 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16)

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Component Tail lights – Left-hand side Sidelight – Left-hand side Brake light – Left-hand side Turn signal – Left-hand side License plate light – Left-hand side Front lights – Left-hand side Sidelight – Left-hand side Turn signal – Left-hand side Front lights – Right-hand side Sidelight – Right-hand side Brake light – Right-hand side Turn signal – Right-hand side License plate light – Right-hand side Front light – Right-hand side Sidelight – Right-hand side Turn signal – Right-hand side

Connector X-082 X-081 X-080 X-049 X-074 X-073 X-078 X-077 X-076 X-048 X-071 X-070

Electrical systems - Harnesses and connectors

CUIL13TR00564AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 07 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Component Switch for the sidelights Switch for the rear work lights Switch for the front work lights Switch for the auxiliary front wheel drive Backup alarm Front work light – Left-hand side Front work light – Right-hand side Rear work light – Left-hand side Rear work light – Right-hand side

Connector X-050, X-051 X-035, X-036 X-037, X-100 X-043, X-045 X-105A, X-105B X-041 X-042 X-039 X-040

Electrical systems - Harnesses and connectors

CUIL13TR00565AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Engine components – Sheet 08 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

Sheet 08 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Component Engine connector Temperature transmitter Air filter is obstructed Fuel shut off Solenoid Oil pressure switch for the engine Cold start Horn Alternator Starter motor

Connector X-006, X-067 X-011 X-009A, X-009B X-013 X-014 X-012 X-020, X-021 X-005, X-007, X-008 X-001

Electrical systems - Harnesses and connectors

CUIL13TR00566AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 09 Reference (1) (2) (3) (4) (5) (6) (7) (8)

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Component Wire harness connector for the upper lights Upper lights Headlight low beam – Right-hand side Headlight main beam – Right-hand side Sidelights – Right-hand side Sidelights – Left-hand side Headlight low beam – Left-hand side Headlight main beam – Left-hand side

Connector X-094 X-094 X-092 X-091 X-095 X-095

Electrical systems - Harnesses and connectors

CUIL13TR00567AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Transmission components – Sheet 10 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

Sheet 10 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9)

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Component Transmission connector Front Wheel Drive (FWD) solenoid Reverse switch – 12x4 transmission Reverse switch – 12x12 transmission Power take-off (PTO) solenoid Pressure switch for the Auxiliary Front Wheel Drive (FWD) Differential lock switch Fuel level sender Reverse light

Connector X-028 -

Electrical systems - Harnesses and connectors

CUIL13TR00568AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Trailer components – Sheet 11 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 11 Reference (1) (2) (3) (4) (5) (6) (7)

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Component Trailer connectors Tail light – Left-hand side Left-hand light – Right-hand side Turn signal – Left-hand side Turn signal – Right-hand side Stop light – Left-hand side Stop light – Right-hand side

Connector -

Electrical systems - Harnesses and connectors

CUIL13TR00569AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema â&#x20AC;&#x201C; instrument panel â&#x20AC;&#x201C; Sheet 12 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

Sheet 12 Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14) (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26)

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Component Dash panel connectors Instrument cluster Water in fule Engine oil pressure Alternator Air filter is obstructed Hour meter Light for the Auxiliary Front Wheel Drive (FWD) Fuel level gauge Water temperature gauge Brakes not locked Grate-type heater Work light lamp Left-hand turn signal Trailer light 1 Trailer light 2 High beam lamp Sidelights and instrument lights Differential lock light Brake fluid level Park brake lamp Right-hand turn signal Power Take-Off (PTO) light Fuel level low Tachometer Steering and transmission oil pressure

Connector X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 X-046 -

Electrical systems - Harnesses and connectors

CUIL13TR00570AA

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Electrical systems - Harnesses and connectors

Wiring harnesses - Electrical schema – Ground points – Sheet 13 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

Sheet 13 Reference (1) (2) (3) (4)

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Component Engine ground Ground 1 Transmission ground Ground 2

Electrical systems - Harnesses and connectors

CUIL13TR00571AA

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Electrical systems - Harnesses and connectors

Wire connectors - Electrical schema index - Model with cab LA LA LA LA LA LA

TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

• Wire connectors - Component diagram 00 (55.100). • Wire connectors - Component diagram 01 (55.100). • Wire connectors - Component diagram 02 (55.100). • Wire connectors - Component diagram 03 (55.100). • Wire connectors - Component diagram 04 (55.100). • Wire connectors - Component diagram 05 (55.100). • Wire connectors - Component diagram 06 (55.100). • Wire connectors - Component diagram 07 (55.100). • Wire connectors - Component diagram 08 (55.100). • Wire connectors - Component diagram 09 (55.100). • Wire connectors - Component diagram 10 (55.100). • Wire connectors - Component diagram 11 (55.100). • Wire connectors - Component diagram 12 (55.100). • Wire connectors - Component diagram 13 (55.100). • Wire connectors - Component diagram 17 (55.100).

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 LA LA LA LA LA LA

X-001 - STARTER MOTOR SOLENOID [ M-001] (82944111) (Female)

82944111

82944111 Pin 1

From X-010M-Male-P-A

Wire EN-1000B

Description EN-1000B

Frame

Color-Size WH - 2.5

SHEET 10

Color-Size BR - 16.0

SHEET 10

X-002 - ALTERNATOR B+ [ G-002] (84401294) (Male)

84401294

84401294 Pin 1

From Wire X-003 (Male) pin 1 STARTER EN-150 MOTOR

Description EN-150

Frame

X-003 - STARTER MOTOR (84417635) (Male) Pin 1 1

From X-098 (Female) pin 2 FUSE X-002 (Male) pin 1 ALTERNATOR B+

Wire EN-150A EN-150

Description EN-150A EN-150

Color-Size BR - 16.0 BR - 16.0

Description

Color-Size R - 50.0

Frame SHEET 10

X-004 - HEATER (Female) Pin 1

From G-001-P-POS

Wire 1B

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Frame SHEET 10

Electrical systems - Harnesses and connectors

X-005 - 4WD SOLENOID VALVE [ Y-003] (87680641) (Female)

87680641

87680641 Pin 1 2

From SP-057B-P-X SP-3025B-P-X

Wire TR-057BB TR-3025C

Description TR-057BB TR-3025C

Color-Size BK - 1.0 YE - 1.0

Frame SHEET 11

X-006 - 4WD DIODE (87475492) (Plug)

87475492

87475492 X-008M - ROOF HARNESS CONNECTORS (87691927) (Female)

87691927

87691927 Pin 1 2 3

From Wire X-021 (Female) pin 1 HEATER RO-1018B X-021 (Female) pin 2 HEATER RO-1017D X-075 (Female) pin 1 RO-4012A BEACON LAMP

Description RO-1018B RO-1017D RO-4012A

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Color-Size GN - 1.5 GN - 2.5 VT - 1.0

Frame SHEET 18 SHEET 13

Electrical systems - Harnesses and connectors

Pin 4 5 6 7 8 9 10 11 12

From SP-997A-P-X SP-1072-P-X X-025 (Female) pin 7 RADIO (POWER) X-028 (Female) pin 1 REAR WIPER SP-666-P-X X-023 (Male) pin 3 FRONT WIPER X-023 (Male) pin 2 FRONT WIPER X-023 (Male) pin 4 FRONT WIPER X-023 (Male) pin 1 FRONT WIPER

Wire RO-997B RO-1012C RO-3003A

Description RO-997B RO-1012C RO-3003A

Color-Size GN - 1.5 VT - 1.5 WH - 1.0

Frame

RO-1038

GN - 1.0

SHEET 18

RO-666 RO-056A

RD - 1.0 VT - 1.0

SHEET 13 SHEET 18

RO-587A

BL - 1.0

RO-1019C

GN - 1.0

RO-1019D

GN - 1.0

SHEET 14 SHEET 13

X-009 - AIR FILTER CLOGGING [ S-001] (87705140) (Female)

87705140

87705140 Pin 1

From SP-57-P-X

Wire EN-057AB

Description EN-057AB

Frame

Color-Size BK - 1.0

SHEET 09

Color-Size GY - 1.0

SHEET 09

X-009A - AIR FILTER CLOGGING [ S-001] (87705140) (Female)

87705140

87705140 Pin 1

From X-010M-Male-P-KK

Wire EN-1005

Description EN-1005

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Frame

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 LA LA LA LA LA LA

X-010F - TO ENGINE HARNESS (47632713) (Female)

47632713

47632713 Pin A AA B CC D DD E FF G GG H HH J KK LL MM NN RR SS UU WW XX

From RH-002-P-E5 RELAY MODULE 2 FH-001-P-2A FUSE MODULE 1 SP-1022-P-X X-054 pin 3 INSTRUMENT CLUSTER SP-155R-P-X X-008F-P-1 SP-155R-P-X X-031 pin 1 RH-001-P-1 RELAY MODULE 1 RH-002-P-B5 RELAY MODULE 2 SP-155G-P-X X-054 pin 7 INSTRUMENT CLUSTER RH-001-P-6 RELAY MODULE 1 X-054 pin 18 INSTRUMENT CLUSTER X-054 pin 38 INSTRUMENT CLUSTER SP-840E-P-X RH-002-P-D5 RELAY MODULE 2 SP-840H-P-X X-054 pin 19 INSTRUMENT CLUSTER FH-001-P-3A FUSE MODULE 1 SP-1027A-P-X X-054 pin 30 INSTRUMENT CLUSTER

Wire CB-1001

Description CB-1001

Color-Size WH - 2.5

SHEET 06

CB-2041

VT - 1.0

SHEET 09

CB-1022C CB-649

BR - 2.5 OR - 0.5

CB-155Y CB-1018A CB-155Z CB-1016 CB-155

GN - 2.5 GN - 1.5 GN - 2.5 VT - 1.0 GN - 2.5

SHEET SHEET SHEET SHEET SHEET

CB-1030

BL - 1.5

SHEET 06

CB-155C CB-2015A

GN - 2.5 WH - 0.5

SHEET 10

CB-155A

GN - 2.5

SHEET 03

CB-1005

GY - 0.5

SHEET 09

CB-3016

GY - 0.5

CB-840G CB-1071B

GN - 1.0 VT - 1.5

CB-840K CB-1035A

GN - 1.0 WH - 0.5

CB-840

GN - 1.5

CB-1027 CB-1006A

BL - 1.5 BR - 0.5

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Frame

10 09 04 10 03

SHEET 07 SHEET 09

SHEET 06 SHEET 10

Electrical systems - Harnesses and connectors

X-011 - WATER TEMPERATURE SENDER [ B-001] (82944111) (Female)

82944111

82944111 Pin 1

From X-010M-Male-P-CC

Wire EN-649

Description EN-649

Frame

Color-Size OR - 1.0

SHEET 09

Color-Size BR - 2.5

SHEET 09

X-012 - THERMOSTARTER [ Y-001] (87747155) (Female)

87747155

87747155 Pin 1

From X-010M-Male-P-B

Wire EN-1022

Description EN-1022

Frame

X-013 - FUEL SHUTT-OFF SOLENOID [ Y-002] (87675193) (Female)

87675193

87675193 Pin 1

From X-010M-Male-P-AA

Wire EN-2041

Description EN-2041

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Color-Size VT - 1.5

Frame SHEET 09

Electrical systems - Harnesses and connectors

X-014 - ENGINE OIL PRESSURE SWITCH [ S-002] (82944111) (Female)

82944111

82944111 Pin 1

From X-010M-Male-P-SS

Wire EN-1035

Description EN-1035

Color-Size WH - 1.0

Frame SHEET 09

X-015 - RH INTERIOR LAMP (87715168) (Female)

87715168

87715168 Pin A B C

From SP-1030-P-X SP-057-P-X SP-1027-P-X

Wire HO-1030G HO-057BV HO-1027D

Description HO-1030G HO-057BV HO-1027D

X-016 - RH INTERIOR LAMP (87715168) (Female)

87715168

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Color-Size BL - 1.0 BK - 1.0 BL - 1.0

Frame SHEET 15

Electrical systems - Harnesses and connectors

Pin A B C

From SP-1030-P-X SP-057-P-X SP-1027-P-X

Wire HO-1030H HO-057BR HO-1027E

Description HO-1030H HO-057BR HO-1027E

Color-Size BL - 1.0 BK - 1.0 BL - 1.0

Frame SHEET 15

X-017 - FRONT HEADLAMPS CONNECTION (87543123) (Female)

87543123

87543123 Pin 2 3 4 5 6

From X-010M-Male-P-NN SP-57-P-X SP-57-P-X X-010M-Male-P-GG X-010M-Male-P-WW

Wire EN-1071 EN-057AE EN-057AC EN-1030 EN-1027

Description EN-1071 EN-057AE EN-057AC EN-1030 EN-1027

Color-Size VT - 1.5 BK - 1.5 BK - 1.5 BL - 1.5 BL - 1.5

Frame SHEET 10

X-018 - (87693711) (Female)

87693711

87693711 Pin A B

From SP-1071-P-X SP-057-P-X

Wire HO-1071E HO-057BS

Description HO-1071E HO-057BS

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Color-Size VT - 1.5 BK - 1.5

Frame SHEET 15

Electrical systems - Harnesses and connectors

X-019 - (87693711) (Female)

87693711

87693711 Pin A B

From SP-1071-P-X SP-057-P-X

Wire HO-1071D HO-057BT

Description HO-1071D HO-057BT

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Color-Size VT - 1.5 BK - 1.5

Frame SHEET 15

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 LA LA LA LA LA LA

X-020 - WORK LAMPS SWITCH [ A-021] (87745329) (Female)

87745329

87745329 Pin 2 3 4 7 8

From SP-1070-P-X RH-003-P-J1 RELAY MODULE 3 SP-1070-P-X RH-003-P-G1 RELAY MODULE 3 SP-1070-P-X

Wire CB-1014H CB-1091

Description CB-1014H CB-1091

Color-Size RD - 1.0 RD - 0.5

CB-1014K CB-1090

RD - 1.0 RD - 0.5

CB-1014G

RD - 1.0

Frame SHEET 14

X-021 - HEATER [ U-012] (87714267) (Female)

87714267

87714267 Pin 1 2 3

From Wire X-008M (Female) pin 1 ROOF RO-1018B HARNESS CONNECTORS X-008M (Female) pin 2 ROOF RO-1017D HARNESS CONNECTORS SP-057CM-P-X RO-057CN

Description RO-1018B

Color-Size GN - 1.5

RO-1017D

GN - 2.5

RO-057CN

BK - 2.5

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Frame SHEET 18

Electrical systems - Harnesses and connectors

X-022 - WORK LAMPS SWITCH LAMP [ A-021] (84131048) (Female)

84131048

84131048 Pin 1 2

From SP-1013D-P-X SP-057AA-P-X

Wire CB-1013T CB-057AC

Description CB-1013T CB-057AC

Color-Size RD - 1.0 BK - 1.0

Frame SHEET 05

X-023 - FRONT WIPER [ U-002] (87709658) (Male)

87709658

87709658 Pin 1

3 4

From X-008M (Female) pin 12 ROOF HARNESS CONNECTORS X-008M (Female) pin 10 ROOF HARNESS CONNECTORS X-008M (Female) pin 9 ROOF HARNESS CONNECTORS X-008M (Female) pin 11 ROOF HARNESS CONNECTORS

Wire RO-1019D

Description RO-1019D

Color-Size GN - 1.0

RO-587A

BL - 1.0

RO-056A

VT - 1.0

RO-1019C

GN - 1.0

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Frame SHEET 18

Electrical systems - Harnesses and connectors

X-024 - RADIO (SPEAKERS) [ U-010] (82008642) (Female)

82008642

82008642 Pin 1 2 3 4

From X-052 (Female) pin 1 REAR SPEAKER X-051 (Female) pin 1 RH SPEAKER X-067 (Female) pin 1 LH SPEAKER X-066 (Female) pin 1 LH SPEAKER

Wire RO-3053

Description RO-3053

Color-Size GY - 0.5

RO-3054

GY - 0.5

RO-3055

GY - 0.5

RO-3056

GY - 0.5

Frame SHEET 13

X-025 - RADIO (POWER) [ U-010] (82008641) (Female)

82008641

82008641 Pin 5 6 7

From Wire SP-666-P-X RO-666C SP-057CM-P-X RO-057CS X-008M (Female) pin 6 ROOF RO-3003A HARNESS CONNECTORS

Description RO-666C RO-057CS RO-3003A

47835583 21/10/2015

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Color-Size RD - 1.0 BK - 1.5 WH - 1.0

Frame SHEET 13 SHEET 08 SHEET 13

Electrical systems - Harnesses and connectors

X-028 - REAR WIPER [ M-005] (87699736) (Female)

87699736

87699736 Pin 1 2

From Wire X-008M (Female) pin 7 ROOF RO-1038 HARNESS CONNECTORS SP-057CM-P-X RO-057CR

Description RO-1038

Color-Size GN - 1.0

RO-057CR

BK - 1.0

Frame SHEET 18

X-029 - HAZARD SWITCH (84289727) (Female)

84289727

84289727 Pin 1 2 3 4 5 6 7

From FH-001-P-4A FUSE MODULE 1 SP-3000-P-X FH-001-P-14A FUSE MODULE 1 SP-3000-P-X SP-044-P-X SP-050-P-X SP-049-P-X

Wire CB-1020

Description CB-1020

Color-Size GN - 1.5

CB-3000B CB-1021

GN - 1.5 VT - 1.5

CB-3000A CB-044B CB-050C CB-049D

GN GN GN GN

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1.5 1.5 1.0 1.0

Frame SHEET 16

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 LA LA LA LA LA LA

X-031 - (87680640) (Female)

87680640

87680640 Pin 1 2 3 4 5 6 7 8 9

From X-010F (Female) pin FF TO ENGINE HARNESS SP-013-P-X SP-013-P-X SP-1024-P-X RH-002-P-A1 RELAY MODULE 2 RH-002-P-B1 RELAY MODULE 2 SP-044-P-X SP-050-P-X SP-049-P-X

Wire CB-1016

Description CB-1016

Color-Size VT - 1.0

CB-013B CB-013A CB-1024 CB-1028A

BL - 1.0 BL - 1.0 RD - 1.0 BL - 0.5

CB-1029A

BL - 0.5

CB-044 CB-050 CB-049

GN - 1.5 GN - 1.0 GN - 1.0

Frame SHEET 10 SHEET 16

SHEET 06

SHEET 16

X-032 - BEACON SWITCH [ SW-044A001] (87745322) (Female)

87745322

87745322 Pin 1 2

From SP-666D-P-X X-008F-Male-P-3

Wire CB-666D CB-4012

Description CB-666D CB-4012

47835583 21/10/2015

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Color-Size RD - 1.0 VT - 1.0

Frame SHEET 04 SHEET 13

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 LA LA LA LA LA LA

X-044 - CLUTCH SWITCH (87687242) (Female)

87687242

87687242 Pin 1 4

From X-084 pin 50 STARTER SWITCH X-097F-P-4

Wire CB-1000

Description CB-1000

Color-Size WH - 1.0

SHEET 16

Frame

CB-1000A

WH - 1.0

SHEET 11

Color-Size GN - 1.0 GN - 1.0

SHEET 07

X-045 - DIODE [ D-001] (84121648) (Female)

84121648

84121648 Pin 1 2

From SP-840H-P-X SP-840M-P-X

Wire CB-840N CB-840P

Description CB-840N CB-840P

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Frame

Electrical systems - Harnesses and connectors

X-048 - (87705881) (Female)

87705881

87705881 Pin 1 4

From SP-057BP-P-X SP-1014-P-X

Wire CB-057CB CB-1014D

Description CB-057CB CB-1014D

Color-Size BK - 1.0 RD - 1.0

Frame SHEET 08 SHEET 15

X-049 - BEACON SWITCH LAMP [ SW-044A001] (84131048) (Female)

84131048

84131048 Pin 1 2

From SP-1013E-P-X SP-057AA-P-X

Wire CB-1013M CB-057AD

Description CB-1013M CB-057AD

47835583 21/10/2015

55.1 [55.100] / 84

Color-Size RD - 1.0 BK - 1.0

Frame SHEET 13 SHEET 08

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 LA LA LA LA LA LA

X-050 - FLASHER UNIT [ K-004] (87746018) (Female)

87746018

87746018 Pin 30 85 86 87 87A

From SP-3000-P-X SP-057BT-P-X X-054 (Female) pin 34 INSTRUMENT CLUSTER X-054 (Female) pin 33 INSTRUMENT CLUSTER SP-044-P-X

Wire CB-3000 CB-057BX CB-1034

Description CB-3000 CB-057BX CB-1034

Color-Size GN - 1.5 BK - 1.5 GN - 0.5

CB-1033

GN - 0.5

CB-044A

GN - 1.5

Frame SHEET 16

X-051 - RH SPEAKER [ L-009] (87705127) (Female)

87705127

87705127 Pin 1

From X-024 (Female) pin 2 RADIO (SPEAKERS)

Wire RO-3054

Description RO-3054

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Color-Size GY - 0.5

Frame SHEET 13

Electrical systems - Harnesses and connectors

X-052 - REAR SPEAKER [ L-009] (87694683) (Female)

87694683

87694683 Pin 1

From X-024 (Female) pin 1 RADIO (SPEAKERS)

Wire RO-3053

Description RO-3053

Frame

Color-Size GY - 0.5

SHEET 13

Color-Size BR - 1.0

SHEET 10

X-053 - ALTERNATOR D+ [ G-002] (87675193) (Female)

87675193

87675193 Pin 1

From X-010M-Male-P-XX

Wire EN-1006

Description EN-1006

X-054 - INSTRUMENT CLUSTER [ U-020] (87358788) (Female)

87358788

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Frame

Electrical systems - Harnesses and connectors

Pin 1 2 3 4 5 7 8 12 16 17 18 19 20 29 30 31 32 33 34 35 37 38 39

From X-097F-Male-P-3 X-097F-Male-P-15 X-010F (Female) pin CC TO ENGINE HARNESS SP-057BT-P-X X-097F-P-16 X-010F (Female) pin HH TO ENGINE HARNESS SP-1000A-P-X SP-1022-P-X SP-1027A-P-X SP-1013-P-X X-010F (Female) pin KK TO ENGINE HARNESS X-010F (Female) pin SS TO ENGINE HARNESS X-097F-P-1 X-097F-Male-P-17 X-010F (Female) pin XX TO ENGINE HARNESS FH-001-P-1A FUSE MODULE 1 FH-001-P-12A FUSE MODULE 1 X-050 pin 87 FLASHER UNIT X-050 pin 86 FLASHER UNIT SP-050-P-X X-097F-Male-P-18 X-010F (Female) pin LL TO ENGINE HARNESS SP-049-P-X

Wire CB-2045A CB-029 CB-649

Description CB-2045A CB-029 CB-649

Color-Size OR - 0.5 GN - 0.5 OR - 0.5

Frame

CB-057BN CB-060K CB-2015A

BK - 0.5 BK - 0.5 WH - 0.5

SHEET 08 SHEET 12 SHEET 10

CB-1000E CB-1022B CB-1027A CB-1013A CB-1005

WH - 0.5 BR - 0.5 BL - 0.5 RD - 0.5 GY - 0.5

SHEET SHEET SHEET SHEET SHEET

CB-1035A

WH - 0.5

CB-3025C CB-3014 CB-1006A

YE - 0.5 RD - 0.5 BR - 0.5

SHEET 11 SHEET 17 SHEET 10

CB-3015

VT - 0.5

SHEET 03

CB-2029

VT - 0.5

SHEET 04

CB-1033 CB-1034 CB-050D CB-7126 CB-3016

GN - 0.5 GN - 0.5 GN - 0.5 GN - 0.5 GY - 0.5

SHEET 16

CB-049E

GN - 0.5

SHEET 17

17 16 17 05 17

SHEET 17

X-056 - THERMO STARTER SWITCH 2 [ S-013] (82944111) (Female)

82944111

82944111 Pin 1

From SP-1022-P-X

Wire CB-1022A

Description CB-1022A

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55.1 [55.100] / 87

Color-Size BR - 2.5

Frame SHEET 16

Electrical systems - Harnesses and connectors

X-056A - THERMO STARTER SWITCH 1 [ S-013] (82944111) (Female)

82944111

82944111 Pin 1

From FH-001-P-10A FUSE MODULE 1

Wire CB-1022

Description CB-1022

Color-Size BR - 2.5

Frame SHEET 16

X-057 - FRONT WIPER SWITCH (Female) X-057 - FRONT WIPER SWITCH (Male)

87686679

87686679 Pin 1 2 4 5 6

From X-008F-Male-P-10 X-008F-Male-P-11 X-008F-Male-P-9 X-119 (Female) pin 1 FRONT WASHER SP-1019-P-X

Wire CB-587 CB-1019A CB-056 CB-085A

Description CB-587 CB-1019A CB-056 CB-085A

Color-Size BL - 1.0 GN - 1.0 VT - 1.0 VT - 1.0

CB-1019E

GN - 1.5

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Frame SHEET 18

SHEET 03

Electrical systems - Harnesses and connectors

X-058 - [ S-023] (82012083) (Female)

82012083

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 06 TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

X-060 - BRAKE OIL LEVEL SWITCH [ S-014] (87675193) (Female)

87675193

87675193 Pin 1

From SP-57-P-X

Wire EN-057AA

Description EN-057AA

Color-Size BK - 1.0

Frame SHEET 09

X-060A - BRAKE OIL LEVEL SWITCH [ S-014] (87675193) (Female)

87675193

87675193 Pin 1

From X-010M-Male-P-LL

Wire EN-3016

Description EN-3016

Color-Size GY - 1.0

SHEET 09

Frame

Wire CB-057CA CB-840B CB-1013S CB-049B

Description CB-057CA CB-840B CB-1013S CB-049B

Color-Size BK - 1.0 GN - 1.5 RD - 1.0 GN - 1.0

SHEET SHEET SHEET SHEET

X-061 - (Female) Pin 1 2 3 4

From SP-057BT-P-X SP-810-P-X SP-1013E-P-X SP-049-P-X

47835583 21/10/2015

55.1 [55.100] / 90

Frame 08 07 05 15

Electrical systems - Harnesses and connectors

X-062 - 4WD SWITCH [ A-005] (87745322) (Female)

87745322

87745322 Pin 2 3

From RH-003-P-H3 RELAY MODULE 3 SP-7080A-P-X

Wire CB-090A

Description CB-090A

Color-Size GN - 0.5

CB-7080F

GN - 0.5

Frame SHEET 16

X-063 - 4WD SWITCH LAMP [ A-005] (84131048) (Female)

84131048

84131048 Pin 1 2

From SP-1013-P-X SP-057AA-P-X

Wire CB-1013K CB-057AM

Description CB-1013K CB-057AM

Frame

Color-Size RD - 1.0 BK - 1.0

SHEET 16 SHEET 08

Color-Size GY - 0.5

SHEET 13

X-066 - LH SPEAKER [ L-010] (87705127) (Female)

87705127

87705127 Pin 1

From X-024 (Female) pin 4 RADIO (SPEAKERS)

Wire RO-3056

Description RO-3056

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Frame

Electrical systems - Harnesses and connectors

X-067 - LH SPEAKER [ L-010] (87694683) (Female)

87694683

87694683 Pin 1

From X-024 (Female) pin 3 RADIO (SPEAKERS)

Wire RO-3055

Description RO-3055

Frame

Color-Size GY - 0.5

SHEET 13

Color-Size BK - 1.0

SHEET 08

X-069 - INDICATOR LAMPS - GND (84253538) (Male)

84253538

84253538 Pin 1

From SP-057BT-P-X

Wire CB-057BY

Description CB-057BY

47835583 21/10/2015

55.1 [55.100] / 92

Frame

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

X-070 - RH INDICATOR LAMPS - TURN (84253538) (Male)

84253538

84253538 Pin 1

From SP-049-P-X

Wire CB-049C

Description CB-049C

Frame

Color-Size GN - 1.0

SHEET 15

Color-Size RD - 1.0

SHEET 15

X-071 - RH INDICATOR LAMPS - SIDE (84253538) (Male)

84253538

84253538 Pin 1

From SP-1013D-P-X

Wire CB-1013B

Description CB-1013B

47835583 21/10/2015

55.1 [55.100] / 93

Frame

Electrical systems - Harnesses and connectors

X-072 - INDICATOR LAMPS-GND (84253538) (Male)

84253538

84253538 Pin 1

From SP-057BT-P-X

Wire CB-057BZ

Description CB-057BZ

Frame

Color-Size BK - 1.0

SHEET 08

Color-Size GN - 1.0

SHEET 15

X-073 - LH INDICATOR LAMPS- TURN (84253538) (Male)

84253538

84253538 Pin 1

From SP-050-P-X

Wire CB-050B

Description CB-050B

X-074 - LH INDICATOR LAMPS-SIDE (84253538) (Male)

84253538

84253538 47835583 21/10/2015

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Frame

Electrical systems - Harnesses and connectors

Pin 1

From SP-1014-P-X

Wire CB-1014B

Description CB-1014B

Frame

Color-Size RD - 1.0

SHEET 15

Color-Size VT - 1.0

SHEET 13

Color-Size BK - 1.0

SHEET 08

X-075 - BEACON LAMP [ LMP-027] (87705127) (Female)

87705127

87705127 Pin 1

From Wire X-008M (Female) pin 3 ROOF RO-4012A HARNESS CONNECTORS

Description RO-4012A

Frame

X-076 - BEACON LAMP [ LMP-027] (87705127) (Female)

87705127

87705127 Pin 1

From SP-057CD-P-X

Wire RO-057CK

Description RO-057CK

X-078 - LH REAR LAMP (87695525) (Female)

87695525

47835583 21/10/2015

55.1 [55.100] / 95

Frame

Electrical systems - Harnesses and connectors

Pin 1 2 3 4

From SP-057BP-P-X SP-810-P-X SP-1014-P-X SP-050-P-X

Wire CB-057CC CB-840C CB-1014E CB-050E

Description CB-057CC CB-840C CB-1014E CB-050E

Frame

Color-Size BK - 1.0 GN - 1.5 RD - 1.0 GN - 1.0

SHEET 08 SHEET 07 SHEET 15

Color-Size BK - 1.0 GN - 1.5

SHEET 14

X-079 - RH REAR WORKLAMP [ LMP-022] (87695525) (Female)

87695525

87695525 Pin 1 3

From SP-057CD-P-X SP-997A-P-X

Wire RO-057CE RO-997D

Description RO-057CE RO-997D

47835583 21/10/2015

55.1 [55.100] / 96

Frame

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 08 TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

X-080 - LH REAR WORKLAMP [ LMP-023] (87695525) (Female)

87695525

87695525 Pin 1 3

From SP-057CD-P-X SP-997A-P-X

Wire RO-057CF RO-997C

Description RO-057CF RO-997C

Color-Size BK - 1.0 GN - 1.5

Frame SHEET 14

X-081 - RH FRONT WORKLAMP [ LMP-025] (87695525) (Female)

87695525

87695525 Pin 1 3

From SP-057CD-P-X SP-1072-P-X

Wire RO-057CG RO-1072A

Description RO-057CG RO-1072A

47835583 21/10/2015

55.1 [55.100] / 97

Color-Size BK - 1.0 VT - 1.5

Frame SHEET 14

Electrical systems - Harnesses and connectors

X-082 - LH FRONT WORKLAMP [ LMP-021] (87695525) (Female)

87695525

87695525 Pin 1 3

From SP-057CD-P-X SP-1072-P-X

Wire RO-057CH RO-1072B

Description RO-057CH RO-1072B

Color-Size BK - 1.0 VT - 1.5

Frame SHEET 14

X-084 - STARTER SWITCH (47726800) (Plug)

47726800

47726800 X-085 - RH INTERIOR LAMP SUIT [ S-021] (87705127) (Female)

87705127

87705127 Pin 1

From SP-3052-P-X

Wire RO-3052B

Description RO-3052B

47835583 21/10/2015

55.1 [55.100] / 98

Color-Size VT - 1.0

Frame SHEET 13

Electrical systems - Harnesses and connectors

X-086 - LH DOOR SWITCH [ S-020] (87705127) (Female)

87705127

87705127 Pin 1

From SP-3052-P-X

Wire RO-3052A

Description RO-3052A

47835583 21/10/2015

55.1 [55.100] / 99

Color-Size VT - 1.0

Frame SHEET 13

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 09 LA LA LA LA LA LA

X-090 - CORNER LIGHTS SWITCH [ SW-002] (87745322) (Female)

87745322

87745322 Pin 1 2

From SP-1072A-P-X RH-002-P-D1 RELAY MODULE 2

Wire CB-1072A CB-1071A

Description CB-1072A CB-1071A

Color-Size VT - 1.5 VT - 0.5

Frame SHEET 07

X-091 - ALTERNADOR W [ G-002] (84352277) (Male)

84352277

84352277 Pin 1

From X-010M-Male-P-HH

Wire EN-2015

Description EN-2015

47835583 21/10/2015

55.1 [55.100] / 100

Color-Size WH - 1.0

Frame SHEET 10

Electrical systems - Harnesses and connectors

X-092 - CORNER LIGHTS SWITCH LAMP [ SW-002] (84131048) (Female)

84131048

84131048 Pin 1 2

From SP-1013-P-X SP-057AA-P-X

Wire CB-1013E CB-057AH

Description CB-1013E CB-057AH

Frame

Color-Size RD - 1.0 BK - 1.0

SHEET 05 SHEET 08

Color-Size GN - 1.0

SHEET 09

Color-Size GN - 1.0

SHEET 09

X-093 - BRAKE LIGHT SW RH [ S-003] (82944111) (Female)

82944111

82944111 Pin 1

From SP-840-P-X

Wire EN-840B

Description EN-840B

Frame

X-093A - BRAKE LIGHT SW RH [ S-003] (82944111) (Female)

82944111

82944111 Pin 1

From X-010M-Male-P-RR

Wire EN-840D

Description EN-840D

47835583 21/10/2015

55.1 [55.100] / 101

Frame

Electrical systems - Harnesses and connectors

X-094 - (Female) Pin 1

From SP-666-P-X

Wire RO-666B

Description RO-666B

Frame

Color-Size RD - 1.0

SHEET 13

X-095 - LH INTERIOR LAMP (87691425) (Female)

87691425

87691425 Pin 1

From SP-3052-P-X

Wire RO-3052C

Description RO-3052C

Color-Size VT - 1.0

SHEET 13

Frame

Wire RO-057CQ

Description RO-057CQ

Color-Size BK - 1.0

SHEET 08

SHEET 11

X-096 - (Female) Pin 1

From SP-057CM-P-X

Frame

X-097M - MAIN HARNESS CONNECTION (87708537) (Female)

87708537

87708537 Pin 1 2 3 4 5 6

From X-112A (Female) pin 1 4WD PRESSURE SWITCH SP-3025B-P-X X-007-Male-P-4 X-007-Male-P-3 X-007-Male-P-2 X-007-Male-P-1

Wire TR-3025A

Description TR-3025A

Color-Size YE - 1.0

TR-3025B TR-2045B TR-1000B TR-1000C TR-7080F

YE - 1.0 OR - 1.0 WH - 1.0 WH - 1.0 GN - 1.0

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Frame

Electrical systems - Harnesses and connectors

Pin 7 8 9 10 11 12 13 14 15 16 17 18

From X-106 (Female) pin 1 X-107 (Female) pin 1 X-109 (Female) pin 1 X-110 (Female) pin 1 X-111 (Female) pin 1 REAR WIPER X-129 (Female) pin A REVERSE SWITCH 12X4 SP-1160A-P-X SP-1160D-P-X X-177 (Female) pin 1 FUEL LEVEL SENDER X-177 (Female) pin 2 FUEL LEVEL SENDER X-114 (Female) pin 1 X-130 (Female) pin 4

Wire TR-349 TR-1014O TR-350B TR-1013P TR-810A

Description TR-349 TR-1014O TR-350B TR-1013P TR-810A

Color-Size BR - 1.0 RD - 1.0 BR - 1.0 RD - 1.0 GN - 1.5

TR-1160J

RD - 1.0

TR-1160W TR-1160D TR-029A

RD - 1.0 RD - 1.0 GN - 1.0

TR-060L

BK - 1.0

TR-3014 TR-7126A

RD - 1.0 GN - 1.0

Frame SHEET 12

X-098 - FUSE [ F-020] (84175730) (Female)

84175730

84175730 Pin 1 2

From Wire EN-155A SP-155-P-X X-003 (Male) pin 1 STARTER EN-150A MOTOR

Description EN-155A EN-150A

47835583 21/10/2015

55.1 [55.100] / 103

Color-Size GN - 16.0 BR - 16.0

Frame SHEET 10

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

X-100 - BRAKE LIGHT SW LH [ S-016] (82944111) (Female)

82944111

82944111 Pin 1

From SP-840-P-X

Wire EN-840A

Description EN-840A

Frame

Color-Size GN - 1.0

SHEET 09

X-100A - BRAKE LIGHT SW LH [ S-016] (82944111) (Female)

82944111

82944111 Pin 1

From X-010M-Male-P-MM

Wire EN-840C

Description EN-840C

Color-Size GN - 1.0

SHEET 09

Frame

Wire RO-666A

Description RO-666A

Color-Size RD - 1.0

SHEET 13

X-101 - (Female) Pin 1

From SP-666-P-X

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Electrical systems - Harnesses and connectors

X-102 - RH INTERIOR LAMP (87691425) (Female)

87691425

87691425 Pin 1

From SP-3052-P-X

Wire RO-3052

Description RO-3052

Frame

Color-Size VT - 1.0

SHEET 13

Color-Size BK - 1.0

SHEET 08

Color-Size BK - 1.0

SHEET 12

X-103 - RH INTERIOR LAMP (87691425) (Female)

87691425

87691425 Pin 1

From SP-057CM-P-X

Wire RO-057CP

Description RO-057CP

Frame

X-105A - REVERSE ALARM 1 [ H-002] (84352277) (Male)

84352277

84352277 Pin 1

From SP-057B-P-X

Wire TR-057BE

Description TR-057BE

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Frame

Electrical systems - Harnesses and connectors

X-105B - REVERSE ALARM 2 [ H-002] (84352277) (Male)

84352277

84352277 Pin 1

From SP-1160D-P-X

Wire TR-1160E

Description TR-1160E

Color-Size RD - 1.0

SHEET 12

Frame

From Wire X-097M (Female) pin 7 MAIN TR-349 HARNESS CONNECTION

Description TR-349

Color-Size BR - 1.0

SHEET 12

Description TR-1014O

Color-Size RD - 1.0

SHEET 12

Description TR-057BC

Color-Size BK - 1.0

SHEET 08

Description TR-350B

Color-Size BR - 1.0

SHEET 12

X-106 - (Female) Pin 1

Frame

X-107 - (Female) Pin 1

From Wire X-097M (Female) pin 8 MAIN TR-1014O HARNESS CONNECTION

Frame

X-108 - (Female) Pin 1

From SP-057B-P-X

Wire TR-057BC

Frame

X-109 - (Female) Pin 1

From Wire X-097M (Female) pin 9 MAIN TR-350B HARNESS CONNECTION

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

X-110 - (Female) Pin 1

From Wire X-097M (Female) pin 10 MAIN TR-1013P HARNESS CONNECTION

Description TR-1013P

Color-Size RD - 1.0

SHEET 12

Frame

Description TR-810A

Color-Size GN - 1.5

SHEET 12

X-111 - REAR WIPER (Female) Pin 1

From Wire X-097M (Female) pin 11 MAIN TR-810A HARNESS CONNECTION

Frame

X-112A - 4WD PRESSURE SWITCH [ S-010] (82944111) (Female)

82944111

82944111 Pin 1

From Wire X-097M (Female) pin 1 MAIN TR-3025A HARNESS CONNECTION

Description TR-3025A

Color-Size YE - 1.0

Frame SHEET 11

X-112B - 4WD PRESSURE SWITCH [ S-010] (82944111) (Female)

82944111

82944111 Pin 1

From SP-057B-P-X

Wire TR-057BF

Description TR-057BF

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Color-Size BK - 1.0

Frame SHEET 11

Electrical systems - Harnesses and connectors

X-114 - (Female) Pin 1 2

From Wire X-097M (Female) pin 17 MAIN TR-3014 HARNESS CONNECTION TR-057BA SP-057B-P-X

Description TR-3014

Color-Size RD - 1.0

SHEET 12

Frame

TR-057BA

BK - 1.0

SHEET 08

X-119 - FRONT WASHER [ M-003] (84015523) (Female)

84015523

84015523 Pin 1 2

From X-057 (Male) pin 5 FRONT WIPER SWITCH SP-057BP-P-X

Wire CB-085A

Description CB-085A

Color-Size VT - 1.0

SHEET 18

CB-057BO

BK - 1.0

SHEET 08

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 12 LA LA LA LA LA LA

X-120 - REAR WASHER [ M-004] (84015523) (Female)

84015523

84015523 Pin 1 2

From X-121 (Female) pin 2 REAR WASHER SWITCH SP-057BP-P-X

Wire CB-086

Description CB-086

Color-Size OR - 1.0

SHEET 18

Frame

CB-057BQ

BK - 1.0

SHEET 08

Color-Size GN - 1.5 OR - 1.0

SHEET 18

X-121 - REAR WASHER SWITCH [ A-001] (87745322) (Female)

87745322

87745322 Pin 1 2

From SP-1019-P-X X-120 (Female) pin 1 REAR WASHER

Wire CB-1019D CB-086

Description CB-1019D CB-086

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Frame

Electrical systems - Harnesses and connectors

X-122 - REAR WASHER SWITCH LAMP [ A-001] (84131048) (Female)

84131048

84131048 Pin 1 2

From SP-1013E-P-X SP-057AA-P-X

Wire CB-1013R CB-057AA

Description CB-1013R CB-057AA

Frame

Color-Size RD - 1.0 BK - 1.0

SHEET 18 SHEET 08

Color-Size VT - 1.0

SHEET 10

Color-Size BK - 1.0

SHEET 10

X-124A - HORN [ H-001] (87675193) (Female)

87675193

87675193 Pin 1

From X-010M-Male-P-FF

Wire EN-1016

Description EN-1016

Frame

X-124B - HORN [ H-001] (87675193) (Female)

87675193

87675193 Pin 1

From SP-57-P-X

Wire EN-057AD

Description EN-057AD

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Electrical systems - Harnesses and connectors

X-126 - AIR CONDITIONER PRESSURE SWITCH [ SW-010] (84015523) (Female)

84015523

84015523 Pin 1 2

From X-010M-Male-P-DD X-127 (Male) pin A AIR CONDITIONER CLUTCH

Wire EN-1018 EN-2100

Description EN-1018 EN-2100

Color-Size GN - 1.5 GN - 1.0

Frame SHEET 09

X-127 - AIR CONDITIONER CLUTCH [ L-001] (87693744) (Male)

87693744

87693744 Pin A

From X-126 (Female) pin 2 AIR CONDITIONER PRESSURE SWITCH

Wire EN-2100

Description EN-2100

X-128 - REVERSE SWITCH 12X12 (87687242) (Female)

87687242

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Color-Size GN - 1.0

Frame SHEET 09

Electrical systems - Harnesses and connectors

Pin 1 4

From SP-1160A-P-X SP-1160D-P-X

Wire TR-1160S TR-1160Y

Description TR-1160S TR-1160Y

Color-Size RD - 1.0 RD - 1.0

Frame SHEET 12

X-129 - REVERSE SWITCH 12X4 (82012093) (Female)

82012093

82012093 Pin A B

From Wire X-097M (Female) pin 12 MAIN TR-1160J HARNESS CONNECTION TR-1160T SP-1160A-P-X

Description TR-1160J

Color-Size RD - 1.0

TR-1160T

RD - 1.0

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Frame SHEET 12

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 13 LA LA LA LA LA LA

X-130 - (82918052) (Female)

82918052

82918052 Pin 1 4

From Wire SP-057B-P-X TR-057BG X-097M (Female) pin 18 MAIN TR-7126A HARNESS CONNECTION

Description TR-057BG TR-7126A

Color-Size BK - 1.0 GN - 1.0

Frame SHEET 08 SHEET 12

X-132 - REVERSE LAMP [ E-008] (82012083) (Female)

82012083

82012083 Pin 1 2

From SP-1160D-P-X SP-057B-P-X

Wire TR-1160F TR-057BD

Description TR-1160F TR-057BD

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Color-Size RD - 1.0 BK - 1.0

Frame SHEET 12

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 17 LA LA LA LA LA LA

X-177 - FUEL LEVEL SENDER [ B-004] (87680259) (Female)

87680259

87680259 Pin 1 2

From Wire X-097M (Female) pin 15 MAIN TR-029A HARNESS CONNECTION X-097M (Female) pin 16 MAIN TR-060L HARNESS CONNECTION

Description TR-029A

Color-Size GN - 1.0

TR-060L

BK - 1.0

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Frame SHEET 12

Electrical systems - Harnesses and connectors

Wire connectors - Electrical schema index - Model without cab TL60E TL75E TL85E TL85E TL95E

LA LA

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 00 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

LA ---

CONNECTOR GND-001 - Ground PIN WIRE NUMBER NUMBER 1 EN-057BF (BK)

CONNECTOR GND-001 - Ground CIRCUIT REFERENCE SP-057BN GND-001 Ground

84123827

ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Ground points – Sheet 13 (55.100)

CONNECTOR GND-004 - Earth PIN WIRE NUMBER NUMBER 1 CB-057A (BK)

CONNECTOR GND-004 - Earth CIRCUIT REFERENCE SP-057A GND-004 Earth

87486317

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ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Ground points – Sheet 13 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR GND-009 - Earth PIN WIRE NUMBER NUMBER 1 CB-057B (BK)

CONNECTOR GND-009 - Earth CIRCUIT REFERENCE SP-057B GND-009 Earth

87486318

ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Ground points – Sheet 13 (55.100)

CONNECTOR K-001 - IGNITION RELAY (I) PIN WIRE NUMBER NUMBER 30 CB-155C (GN)

CB-057BA (BK)

CB-1000 (WH)

CB-1001A (WH)

CONNECTOR K-001 - IGNITION RELAY (I) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-155B K-001 IGNITION RELAY (I) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) SP-057BC K-001 IGNITION RELAY Wiring harnesses - Electrical schema – Main wire harness – (I) Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical X-028 Transmission system connection K-001 IGNITION RELAY schema – Transmission components – Sheet 10 (55.100) (I) K-001 IGNITION RELAY (I) SP-1001A Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

82918443

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Electrical systems - Harnesses and connectors

CONNECTOR K-003 - HIGH BEAM (III) PIN WIRE NUMBER NUMBER 30 CB-1028 (BL)

CONNECTOR K-003 - HIGH BEAM (III) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022 FUSES BOX K-003 HIGH BEAM (III)

CB-057AM (BK)

K-003 HIGH BEAM (III) SP-057BC

CB-1027 (BL)

CB-1026 (BL)

X-031 Lights control K-003 HIGH BEAM (III) K-003 HIGH BEAM (III) SP-1026

82918444

Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

CONNECTOR K-005 - DIP BEAM (V) PIN WIRE NUMBER NUMBER 30 CB-1030G (BL)

CB-1030 (BL)

CB-1030J (BL)

CONNECTOR K-005 - DIP BEAM (V) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) X-031 Lights control K-005 DIP Wiring harnesses - Electrical BEAM (V) schema – Sheet 05 (55.100) X-022 FUSES BOX K-005 DIP BEAM Wiring harnesses - Electrical schema – Main wire harness (V) of the header – Relay and fuse compartment – Sheet 01 (55.100)

K-005 DIP BEAM (V) X-067 Engine connector

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Electrical systems - Harnesses and connectors

83990049

CONNECTOR K-006 - FLASHER UNIT (VI) PIN WIRE NUMBER NUMBER 30 CB-3000 (GN) 86

CB-1034 (GN)

CB-1033 (GN)

87A

CB-44A (GN)

CONNECTOR K-006 - FLASHER UNIT (VI) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-032 Hazard switch K-006 Wiring harnesses - Electrical FLASHER UNIT (VI) schema – Sheet 05 (55.100) K-006 FLASHER UNIT (VI) SP-1034 Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) K-006 FLASHER UNIT (VI) SP-1033 Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical K-006 FLASHER UNIT (VI) SP-44 schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

83990049

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Electrical systems - Harnesses and connectors

CONNECTOR K-007 - 4WD (VII) PIN WIRE NUMBER NUMBER 30 CB-3025D (YE)

CB-810A (GN)

87A

CB-3025 (YE)

CONNECTOR K-007 - 4WD (VII) CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) Wiring harnesses - Electrical K-008 BRAKE LIGHT (VIII) K-007 schema – Main wire harness – 4WD (VII) Relay and fuse compartment – Sheet 02 (55.100) K-007 4WD (VII) X-028 Transmission Wiring harnesses - Electrical schema – Main wire harness – system connection Relay and fuse compartment – Sheet 02 (55.100) X-043 4WD switch K-007 4WD (VII)

83990049

CONNECTOR K-008 - BRAKE LIGHT (VIII) PIN WIRE NUMBER NUMBER 30 CB-840A (GN)

CONNECTOR K-008 - BRAKE LIGHT (VIII) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-065 Stop lights switch K-008 BRAKE LIGHT (VIII)

CB-840C (GN)

SP-840 K-008 BRAKE LIGHT (VIII)

CB-810A (GN)

K-008 BRAKE LIGHT (VIII) K-007 4WD (VII)

87A

CB-810H (GN)

K-008 BRAKE LIGHT (VIII) SP-810

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Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

Electrical systems - Harnesses and connectors

83990049

CONNECTOR K-009 - BRAKE LIGHT (IX) PIN WIRE NUMBER NUMBER 30 CB-840E (GN)

CONNECTOR K-009 - BRAKE LIGHT (IX) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-090A K-009 BRAKE LIGHT (IX)

CB-840F (GN)

K-009 BRAKE LIGHT (IX) SP-840

CB-810 (GN)

K-009 BRAKE LIGHT (IX) SP-810

83990049

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR RES-001 - RES-001 CONNECTOR RES-001 - RES-001 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 1 CB-1033A (GN)

RES-001 SP-1033

RES-001 SP-057A

CB-057AJ (BK)

Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

CONNECTOR RES-002 - RES-002 CONNECTOR RES-002 - RES-002 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 1 CB-1034A (GN)

RES-002 SP-1034

RES-002 SP-057A

CB-057AH (BK)

CONNECTOR X-001 - Starter Motor Solenoid CONNECTOR X-001 - Starter Motor Solenoid PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER Wiring harnesses - Electrical 85 EN-1001 (WH) SP-1001 X-001 Starter Motor schema – Engine components – Solenoid Sheet 08 (55.100)

82944111

CONNECTOR X-002 - Starter Motor PIN WIRE NUMBER NUMBER 1 EN-150B (BR)

CONNECTOR X-002 - Starter Motor CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-005 Alternator B+ X-002 Starter Motor

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Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-004 - Cab Power Supply Connector CONNECTOR X-004 - Cab Power Supply Connector WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 CB-150 (BR)

X-004 Cab Power Supply Connector Wiring harnesses - Electrical schema Main wire harness of the X-038 Main Cab Fuse header – Switches – Sheet 04 (55.100)

CONNECTOR X-005 - Alternator B+ PIN WIRE NUMBER NUMBER B+ EN-150B (BR)

CONNECTOR X-005 - Alternator B+ CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-005 Alternator B+ X-002 Starter Motor

Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

CONNECTOR X-006 - Engine connector PIN WIRE NUMBER NUMBER 1 2 EN-1005 (GY)

6 7 8

10 11 12

EN-1073C (VT)

EN-1035 (WH)

EN-376A (VT)

EN-39 (GN)

EN-2041 (VT)

EN-1022G (BR)

EN-1001D (WH)

EN-2015 (WH)

EN-1001E (WH)

CONNECTOR X-006 - Engine connector CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-006 Engine connector X-009B Air filter clogging

Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100) X-006 Engine connector X-096F Wiring harnesses - Electrical Front headlamps connection schema – Engine components Sheet 08 (55.100) X-006 Engine connector X-014 Wiring harnesses - Electrical Engine oil pressure switch schema – Engine components Sheet 08 (55.100) X-006 Engine connector X-021 Horn Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100) X-006 Engine connector X-011 Water Wiring harnesses - Electrical temperature sender schema – Engine components Sheet 08 (55.100) X-006 Engine connector X-013 Fuel Wiring harnesses - Electrical shutt-off solenoid schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical X-006 Engine connector SP-1022 schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical SP-1001 X-006 Engine connector schema – Engine components Sheet 08 (55.100) X-008 Alternador W X-006 Engine Wiring harnesses - Electrical connector schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical X-006 Engine connector SP-1001 schema – Engine components Sheet 08 (55.100)

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–

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 16 EN-1030D (BL)

EN-1006 (BR)

EN-1022H (BR)

EN-1027T (BL)

CONNECTOR X-006 - Engine connector CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-006 Engine connector X-096F Front headlamps connection X-006 Engine connector X-007 ALTERNATOR D+ X-006 Engine connector SP-1022

X-006 Engine connector X-096F Front headlamps connection

Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100) Wiring harnesses - Electrical schema – Engine components Sheet 08 (55.100)

–

84284806

CONNECTOR X-007 - ALTERNATOR D+ PIN WIRE NUMBER NUMBER D+ EN-1006 (BR)

CONNECTOR X-007 - ALTERNATOR D+ CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-006 Engine connector X-007 ALTERNATOR D+

87675193

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Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-008 - Alternador W PIN WIRE NUMBER NUMBER W EN-2015 (WH)

CONNECTOR X-008 - Alternador W CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-008 Alternador W X-006 Engine connector

84153167

Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

CONNECTOR X-009A - Air filter clogging PIN WIRE NUMBER NUMBER 1 EN-057BE (BK)

CONNECTOR X-009A - Air filter clogging CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-009A Air filter clogging SP-057BN

87705140

Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

CONNECTOR X-009B - Air filter clogging CONNECTOR X-009B - Air filter clogging WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 EN-1005 (GY)

X-006 Engine connector X-009B Air filter clogging

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Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

Electrical systems - Harnesses and connectors

87705140

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 01 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

CONNECTOR K-016 - REVERSE ALARM (E) PIN WIRE NUMBER NUMBER 30 CB-1160V (RD)

CB-057AU (BK)

CB-1160K (RD)

CB-1160X (RD)

CONNECTOR K-016 - REVERSE ALARM (E) CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical K-016 REVERSE ALARM (E) schema – Main wire harness – SP-057BC Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical X-028 Transmission system connection K-016 REVERSE ALARM schema – Transmission components – Sheet 10 (55.100) (E) K-016 REVERSE ALARM (E) X-028 Wiring harnesses - Electrical schema – Main wire harness – Transmission system connection Relay and fuse compartment – Sheet 02 (55.100) SP-1160 K-016 REVERSE ALARM (E)

82918442

CONNECTOR K-017 - PTO (F) CONNECTOR K-017 - PTO (F) CIRCUIT REFERENCE

PIN WIRE NUMBER NUMBER 30 CB-2042N (OR)

K-017 PTO (F) SP-2042N

CB-057AT (BK)

K-017 PTO (F) SP-057BC

CB-2042F (OR)

X-086 Rear PTO Switch K-017 PTO (F)

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ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 87 CB-2042C (OR)

CONNECTOR K-017 - PTO (F) CIRCUIT REFERENCE K-017 PTO (F) SP-2042C

82918442

ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

CONNECTOR K-018 - PTO (G) CONNECTOR K-018 - PTO (G) CIRCUIT REFERENCE

PIN WIRE NUMBER NUMBER 30 CB-2042G (OR)

K-018 PTO (G) SP-2042N

CB-057AX (BK)

K-018 PTO (G) SP-057BC

CB-2042P (OR)

K-018 PTO (G) SP-2042E

CB-2042J (OR)

X-022 FUSES BOX K-018 PTO (G)

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ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR K-019 - CORNER LIGHTS (A) CONNECTOR K-019 - CORNER LIGHTS (A) WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 30 CB-1073E (VT)

CB-057AV (BK)

CB-1072 (VT)

CB-1073D (VT)

X-022 FUSES BOX K-019 CORNER Wiring harnesses - Electrical schema – Main wire harness LIGHTS (A) of the header – Relay and fuse compartment – Sheet 01 (55.100) SP-057BC K-019 CORNER LIGHTS Wiring harnesses - Electrical schema – Main wire harness (A) of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-050 Corner Lights switch K-019 schema – Switches for the CORNER LIGHTS (A) auxiliary front wheel drive and work lights – Sheet 07 (55.100) K-019 CORNER LIGHTS (A) X-067 Wiring harnesses - Electrical schema – Main wire harness – Engine connector Relay and fuse compartment – Sheet 02 (55.100)

82918442

CONNECTOR X-011 - Water temperature sender CONNECTOR X-011 - Water temperature sender PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 X-006 Engine connector X-011 Water Wiring harnesses - Electrical EN-39 (GN) temperature sender schema – Engine components – Sheet 08 (55.100)

82944111

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Electrical systems - Harnesses and connectors

CONNECTOR X-012 - Thermostarter PIN WIRE NUMBER NUMBER 1 EN-1022 (BR)

CONNECTOR X-012 - Thermostarter CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1022 X-012 Thermostarter

87747155

Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

CONNECTOR X-013 - Fuel shutt-off solenoid CONNECTOR X-013 - Fuel shutt-off solenoid PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 X-006 Engine connector X-013 Fuel Wiring harnesses - Electrical EN-2041 (VT) shutt-off solenoid schema – Engine components – Sheet 08 (55.100)

87675193

CONNECTOR X-014 - Engine oil pressure switch CONNECTOR X-014 - Engine oil pressure switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 EN-1035 (WH)

X-006 Engine connector X-014 Engine oil pressure switch

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Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 02 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA --LA ---

CONNECTOR X-020 - Horn PIN WIRE NUMBER NUMBER 1 EN-057BD (BK)

CONNECTOR X-020 - Horn CIRCUIT REFERENCE X-020 Horn SP-057BN

87675193

ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

CONNECTOR X-021 - Horn PIN WIRE NUMBER NUMBER 1 EN-376A (VT)

CONNECTOR X-021 - Horn CIRCUIT REFERENCE

ELECTRICAL SCHEMATIC FRAME

X-006 Engine connector X-021 Horn Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100)

87675193

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Electrical systems - Harnesses and connectors

CONNECTOR X-022 - FUSES BOX PIN WIRE NUMBER NUMBER 3 CB-1024 (RD) 7

CB-1028A (BL)

CB-1029 (BL)

CB-1071 (VT)

CB-155A (GN)

CB-71 (WH)

CB-1011B (YE)

CB-155E (GN)

CB-1011A (YE)

CB-1000C (WH)

CB-1022B (BR)

CB-1013F (RD)

CB-1014B (RD)

CB-1028 (BL)

CB-1030J (BL)

CONNECTOR X-022 - FUSES BOX CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical SP-155 X-022 FUSES BOX schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical SP-155 X-022 FUSES BOX schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical SP-155 X-022 FUSES BOX schema Main wire harness of the header – Splices – Sheet 03 (55.100) X-033 Starter switch X-022 FUSES Wiring harnesses - Electrical schema – Sheet 05 (55.100) BOX Wiring harnesses - Electrical SP-1011 X-022 FUSES BOX schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical SP-155B X-022 FUSES BOX schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical SP-1011 X-022 FUSES BOX schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical SP-1000C X-022 FUSES BOX schema – Sheet 05 (55.100) X-033 Starter switch X-022 FUSES Wiring harnesses - Electrical schema – Sheet 05 (55.100) BOX Wiring harnesses - Electrical X-022 FUSES BOX SP-1013F schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX SP-1024A schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX K-003 HIGH schema – Main wire harness BEAM (III) of the header – Relay and fuse compartment – Sheet 01 (55.100) X-022 FUSES BOX K-005 DIP BEAM Wiring harnesses - Electrical schema – Main wire harness (V) of the header – Relay and fuse compartment – Sheet 01 (55.100) X-031 Lights control X-022 FUSES BOX SP-155 X-022 FUSES BOX

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Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 9A CB-1073E (VT)

10A

CB-1021 (VT)

11A

CB-376B (VT)

12A

CB-1003 (GN)

13A

CB-2041A (VT)

15A

CB-1072A (VT)

16A

CB-1160 (RD)

17A

CB-90A (GN)

18A

CB-2042D (OR) CB-2042J (OR)

19A

CB-155F (GN)

20A

CB-1097 (RD)

21A

CB-1020 (GN)

22A

CB-1096 (RD)

23A

CB-1000D (WH)

CONNECTOR X-022 - FUSES BOX CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022 FUSES BOX K-019 CORNER Wiring harnesses - Electrical schema – Main wire harness LIGHTS (A) of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-032 Hazard schema – Main wire harness switch of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-031 Lights schema – Main wire harness control of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX SP-1003 schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-067 Engine schema – Main wire harness connector of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX SP-1072A schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical SP-1160 X-022 FUSES BOX schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX SP-090A schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) X-022 FUSES BOX X-087 Rear PTO Wiring harnesses - Electrical schema – Main wire harness Switch X-022 FUSES BOX K-018 PTO (G) of the header – Relay and fuse compartment – Sheet 01 (55.100) X-022 FUSES BOX X-046 Instrument Wiring harnesses - Electrical schema – Main wire harness cluster of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-037 Front schema – Main wire harness WorkLamp SW 1 of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-032 Hazard schema – Main wire harness switch of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-035 Rear schema – Main wire harness Worklamp SW 1 of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-022 FUSES BOX X-066 Safety schema – Main wire harness Starter Switch of the header – Relay and fuse compartment – Sheet 01 (55.100)

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Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 24A CB-1022D (BR)

CONNECTOR X-022 - FUSES BOX CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022 FUSES BOX X-057 Thermostarter switch

Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

CONNECTOR X-027 - Maxifuse Holder 1 PIN WIRE NUMBER NUMBER 1 CB-155G (GN)

CB-155 (GN)

CONNECTOR X-027 - Maxifuse Holder 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-155G X-027 Maxifuse Holder 1

X-027 Maxifuse Holder 1 SP-155

84153389

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

CONNECTOR X-028 - Transmission system connection PIN NUMBER 1

CONNECTOR X-028 - Transmission system connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME -

CB-1000 (WH)

X-028 Transmission system connection K-001 IGNITION RELAY (I) SP-050A X-028 Transmission system connection SP-049A X-028 Transmission system connection SP-1013F X-028 Transmission system connection

CB-350C (BL)

CB-349C (BL)

CB-1013C (RD)

CB-1014E (RD)

SP-1024A X-028 Transmission system connection

CB-810F (RD)

SP-810 X-028 Transmission system connection

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Wiring harnesses - Electrical schema – Transmission components – Sheet 10 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-028 - Transmission system connection WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 8 CB-3025 (YE)

CB-2042 (OR)

10 11 12

CB-1000E (WH)

CB-1160K (RD)

CB-29 (GN)

CB-3045 (YE)

CB-7120 (YE)

CB-1160X (RD)

CB-1160U (RD)

CB-1003A (GN)

CB-1160G (RD)

K-007 4WD (VII) X-028 Transmission Wiring harnesses - Electrical schema – Main wire harness – system connection Relay and fuse compartment – Sheet 02 (55.100) X-028 Transmission system Wiring harnesses - Electrical connection SP-2042C schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical X-066 Safety Starter Switch X-028 schema – Sheet 05 (55.100) Transmission system connection Wiring harnesses - Electrical X-028 Transmission system connection K-016 REVERSE ALARM schema – Transmission components – Sheet 10 (55.100) (E) X-046 Instrument cluster X-028 Wiring harnesses - Electrical Transmission system connection schema – instrument panel – Sheet 12 (55.100) X-028 Transmission system Wiring harnesses - Electrical connection X-046 Instrument cluster schema – Transmission components – Sheet 10 (55.100) X-046 Instrument cluster X-028 Wiring harnesses - Electrical Transmission system connection schema – Transmission components – Sheet 10 (55.100) K-016 REVERSE ALARM (E) X-028 Wiring harnesses - Electrical schema – Main wire harness – Transmission system connection Relay and fuse compartment – Sheet 02 (55.100) SP-1160 X-028 Transmission system Wiring harnesses - Electrical schema Main wire harness of connection the header – Splices – Sheet 03 (55.100) SP-1003 X-028 Transmission system Wiring harnesses - Electrical schema Main wire harness of connection the header – Splices – Sheet 03 (55.100) X-028 Transmission system Wiring harnesses - Electrical connection X-105B Reverse Alarm 2 schema – Transmission components – Sheet 10 (55.100)

84284807

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Electrical systems - Harnesses and connectors

CONNECTOR X-029 - Maxifuse Holder 1 PIN WIRE NUMBER NUMBER 1 CB-155H (GN)

CB-155B (GN)

CONNECTOR X-029 - Maxifuse Holder 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-155G X-029 Maxifuse Holder 1

X-029 Maxifuse Holder 1 SP-155B

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Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 03 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

CONNECTOR X-031 - Lights control PIN WIRE NUMBER NUMBER 1 CB-376 (VT)

CONNECTOR X-031 - Lights control CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-031 Lights control X-067 Engine connector X-022 FUSES BOX X-031 Lights control

CB-376B (VT)

CB-1023C (BR)

SP-155 X-031 Lights control

CB-1024 (RD)

CB-1027 (BL)

CB-1030 (BL)

CB-44 (GN)

X-031 Lights control X-022 FUSES BOX X-031 Lights control K-003 HIGH BEAM (III) X-031 Lights control K-005 DIP BEAM (V) SP-44 X-031 Lights control

CB-50A (GN)

X-031 Lights control SP-050A

CB-49A (GN)

X-031 Lights control SP-049A

CB-3005A (GN)

SP-3005 X-031 Lights control

CB-3004A (GN)

SP-3004 X-031 Lights control

CB-3001 (GN)

CB-3002 (GN)

X-032 Hazard switch X-031 Lights control X-032 Hazard switch X-031 Lights control

87690974

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Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-032 - Hazard switch PIN WIRE NUMBER NUMBER D CB-3000 (GN) H

CB-3002 (GN)

CB-44B (GN)

CB-3001 (GN)

CB-1020 (GN)

CB-44C (GN)

CB-1021 (VT)

CONNECTOR X-032 - Hazard switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-032 Hazard switch K-006 FLASHER UNIT (VI) X-032 Hazard switch X-031 Lights control SP-44 X-032 Hazard switch X-032 Hazard switch X-031 Lights control X-022 FUSES BOX X-032 Hazard switch

X-032 Hazard switch X-034 Hazard switch X-022 FUSES BOX X-032 Hazard switch

87745327

Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

CONNECTOR X-033 - Starter switch PIN WIRE NUMBER NUMBER 1 CB-155D (GN)

CONNECTOR X-033 - Starter switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-155B X-033 Starter switch

CB-1022B (BR)

CB-71 (WH)

CB-1000F (WH)

X-033 Starter switch X-022 FUSES BOX X-033 Starter switch X-022 FUSES BOX SP-1000C X-033 Starter switch

CB-1011C (YE)

X-033 Starter switch SP-1011

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

Electrical systems - Harnesses and connectors

87745335

CONNECTOR X-034 - Hazard switch PIN WIRE NUMBER NUMBER 1 CB-057AG (BK) 2

CB-44C (GN)

CONNECTOR X-034 - Hazard switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-034 Hazard switch SP-057BB X-032 Hazard switch X-034 Hazard switch

84131048

Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

CONNECTOR X-035 - Rear Worklamp SW 1 PIN WIRE NUMBER NUMBER 1 CB-1096B (RD)

CB-1096 (RD)

CONNECTOR X-035 - Rear Worklamp SW 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-035 Rear Worklamp SW 1 SP-1096B

X-022 FUSES BOX X-035 Rear Worklamp SW 1

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Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

Electrical systems - Harnesses and connectors

87717631

CONNECTOR X-036 - Rear Worklamp SW 2 PIN WIRE NUMBER NUMBER 1 CB-057AE (BK)

CB-1096D (RD)

CONNECTOR X-036 - Rear Worklamp SW 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) SP-1096B X-036 Rear Worklamp SW Wiring harnesses - Electrical schema – Switches for the 2 auxiliary front wheel drive and work lights – Sheet 07 (55.100) X-036 Rear Worklamp SW 2 SP-057BB

84131048

CONNECTOR X-037 - Front WorkLamp SW 1 CONNECTOR X-037 - Front WorkLamp SW 1 PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 Wiring harnesses - Electrical CB-1097 (RD) X-022 FUSES BOX X-037 Front schema – Main wire harness WorkLamp SW 1 of the header – Relay and fuse compartment – Sheet 01 (55.100) 5 Wiring harnesses - Electrical CB-1097A (RD) X-037 Front WorkLamp SW 1 schema – Switches for the SP-1097A auxiliary front wheel drive and work lights – Sheet 07 (55.100)

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Electrical systems - Harnesses and connectors

87717631

CONNECTOR X-038 - Main Cab Fuse PIN WIRE NUMBER NUMBER 1 CB-150 (BR)

CB-155K (GN)

CONNECTOR X-038 - Main Cab Fuse CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-004 Cab Power Supply Connector Wiring harnesses - Electrical schema – Engine components – X-038 Main Cab Fuse Sheet 08 (55.100) Wiring harnesses - Electrical X-038 Main Cab Fuse SP-155G schema Main wire harness of the header – Switches – Sheet 04 (55.100)

84175730

CONNECTOR X-039 - LH Rear Worklamp PIN WIRE NUMBER NUMBER 1 CB-1096E (RD)

CB-057C (BK)

CONNECTOR X-039 - LH Rear Worklamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1096B X-039 LH Rear Worklamp Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) X-039 LH Rear Worklamp SP-057B Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

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Electrical systems - Harnesses and connectors

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 04 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA ---

CONNECTOR X-040 - RH Rear Worklamp PIN WIRE NUMBER NUMBER 1 CB-1096C (RD)

CB-057D (BK)

CONNECTOR X-040 - RH Rear Worklamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1096B X-040 RH Rear Worklamp Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) X-040 RH Rear Worklamp SP-057B Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

87695909

CONNECTOR X-041 - Front Worklamp LH CONNECTOR X-041 - Front Worklamp LH WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 CB-1097B (RD)

SP-1097A X-041 Front Worklamp LH Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

87705127

CONNECTOR X-042 - Front Worklamp RH PIN WIRE NUMBER NUMBER 1 CB-1097C (RD)

CONNECTOR X-042 - Front Worklamp RH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1097A X-042 Front Worklamp RH Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) 47835583 21/10/2015

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Electrical systems - Harnesses and connectors

87705127

CONNECTOR X-043 - 4WD switch CONNECTOR X-043 - 4WD switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 2 CB-90B (GN)

SP-090A X-043 4WD switch

X-043 4WD switch K-007 4WD (VII)

CB-3025D (YE)

87745322

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

CONNECTOR X-044 - Thermostarter switch PIN WIRE NUMBER NUMBER 1 CB-1014F (RD)

CB-057AF (BK)

CONNECTOR X-044 - Thermostarter switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1024A X-044 Thermostarter switch

X-044 Thermostarter switch SP-057BB

84131048

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-045 - 4WD switch CONNECTOR X-045 - 4WD switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 1 CB-1014G (RD)

SP-1024A X-045 4WD switch

X-045 4WD switch SP-057BB

CB-057AC (BK)

84131048

CONNECTOR X-046 - Instrument cluster PIN WIRE NUMBER NUMBER 1 CB-2042M (OR)

CONNECTOR X-046 - Instrument cluster CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-046 Instrument cluster SP-2042C

CB-29 (GN)

X-046 Instrument cluster X-028 Transmission system connection

CB-39A (GN)

X-067 Engine connector X-046 Instrument cluster

CB-057AB (BK)

X-046 Instrument cluster SP-057A

CB-057AA (BK)

X-046 Instrument cluster SP-057A

CB-2015A (WH)

X-067 Engine connector X-046 Instrument cluster

CB-1000G (WH)

SP-1000C X-046 Instrument cluster

CB-3016 (GY)

X-061 Brake oil level switch X-046 Instrument cluster

CB-7120 (YE)

X-046 Instrument cluster X-028 Transmission system connection

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Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (55.100) Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (55.100) Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (55.100) Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (55.100) Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100) Wiring harnesses - Electrical schema – Transmission components – Sheet 10 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 13 CB-3014 (RD)

CB-1135 (GN)

CB-3008 (BL)

CB-1026A (BL)

CB-1013 (RD)

CB-1035A (WH)

CB-3045 (YE)

CB-1006A (BR)

CB-1003B (GN)

CB-155F (GN)

CB-1033B (GN)

CB-1034B (GN)

CB-3005 (GN)

CB-1005A (GY)

CB-3004 (GN)

CONNECTOR X-046 - Instrument cluster CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-059 Handbrake switch X-046 Instrument cluster

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100) SP-1022A X-046 Instrument cluster Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) SP-1096B X-046 Instrument cluster Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100) Wiring harnesses - Electrical X-046 Instrument cluster SP-1026 schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) SP-1013F X-046 Instrument cluster Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) X-046 Instrument cluster X-067 Wiring harnesses - Electrical Engine connector schema – Trailer components – Sheet 11 (55.100) X-028 Transmission system Wiring harnesses - Electrical connection X-046 Instrument cluster schema – Trailer components – Sheet 11 (55.100) X-046 Instrument cluster X-067 Wiring harnesses - Electrical Engine connector schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical SP-1003 X-046 Instrument cluster schema Main wire harness of the header – Splices – Sheet 03 (55.100) X-022 FUSES BOX X-046 Instrument Wiring harnesses - Electrical schema – Main wire harness cluster of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical X-046 Instrument cluster SP-1033 schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical X-046 Instrument cluster SP-1034 schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical SP-3005 X-046 Instrument cluster schema – Sheet 05 (55.100) X-046 Instrument cluster X-067 Wiring harnesses - Electrical Engine connector schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical SP-3004 X-046 Instrument cluster schema – Sheet 05 (55.100)

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Electrical systems - Harnesses and connectors

CONNECTOR X-048 - RH License Plate PIN WIRE NUMBER NUMBER 1 CB-057BZ (BK)

CB-978 (WH)

CONNECTOR X-048 - RH License Plate CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-048 RH License Plate SP-057B

SP-1013F X-048 RH License Plate

87695525

Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-049 - LH License Plate PIN WIRE NUMBER NUMBER 1 CB-057AR (BK)

CB-978A (WH)

CONNECTOR X-049 - LH License Plate CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-049 LH License Plate SP-057B

SP-1024A X-049 LH License Plate

87695525

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 05 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

CONNECTOR X-050 - Corner Lights switch PIN WIRE NUMBER NUMBER 1 CB-1072B (VT)

CB-1072 (VT)

CONNECTOR X-050 - Corner Lights switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1072A X-050 Corner Lights switch

X-050 Corner Lights switch K-019 CORNER LIGHTS (A)

87745322

CONNECTOR X-051 - Corner Lights switch CONNECTOR X-051 - Corner Lights switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 CB-1072C (RD)

CB-057AK (BK)

SP-1072A X-051 Corner Lights switch

X-051 Corner Lights switch SP-057BB

84131048

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Electrical systems - Harnesses and connectors

CONNECTOR X-057 - Thermostarter switch CONNECTOR X-057 - Thermostarter switch WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN NUMBER 1 CB-1022A (BR) 2

CB-1022D (BR)

X-057 Thermostarter switch SP-1022A X-022 FUSES BOX X-057 Thermostarter switch

87745322

Wiring harnesses - Electrical schema – Sheet 05 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

CONNECTOR X-058 - Handbrake switch PIN WIRE NUMBER NUMBER 1 CB-3012 (GN)

CONNECTOR X-058 - Handbrake switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1003 X-058 Handbrake switch

87694682

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-059 - Handbrake switch PIN WIRE NUMBER NUMBER 1 CB-3014 (RD)

CONNECTOR X-059 - Handbrake switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-059 Handbrake switch X-046 Instrument cluster

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Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

Electrical systems - Harnesses and connectors

87694682

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 06 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA ---

CONNECTOR X-060 - Brake oil level switch PIN WIRE NUMBER NUMBER 1 CB-7995 (PK)

CONNECTOR X-060 - Brake oil level switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1003 X-060 Brake oil level switch Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

87675193

CONNECTOR X-061 - Brake oil level switch PIN WIRE NUMBER NUMBER 1 CB-3016 (GY)

CONNECTOR X-061 - Brake oil level switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-061 Brake oil level switch X-046 Instrument cluster

87675193

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Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-062 - Stop lights switch PIN WIRE NUMBER NUMBER 1 CB-840B (GN)

CONNECTOR X-062 - Stop lights switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-090A X-062 Stop lights switch

82944111

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-063 - Stop lights switch PIN WIRE NUMBER NUMBER 1 CB-840 (GN)

CONNECTOR X-063 - Stop lights switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-063 Stop lights switch SP-840

82944111

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

CONNECTOR X-064 - Stop lights switch PIN WIRE NUMBER NUMBER 1 CB-840D (GN)

CONNECTOR X-064 - Stop lights switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-090A X-064 Stop lights switch

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

Electrical systems - Harnesses and connectors

82944111

CONNECTOR X-065 - Stop lights switch PIN WIRE NUMBER NUMBER 1 CB-840A (GN)

CONNECTOR X-065 - Stop lights switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-065 Stop lights switch K-008 BRAKE LIGHT (VIII)

82944111

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

CONNECTOR X-066 - Safety Starter Switch PIN WIRE NUMBER NUMBER 1 CB-1000D (WH)

CB-1000E (WH)

CONNECTOR X-066 - Safety Starter Switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022 FUSES BOX X-066 Safety Starter Switch

X-066 Safety Starter Switch X-028 Transmission system connection

87746043

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Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-067 - Engine connector PIN WIRE NUMBER NUMBER 1 2 CB-1005A (GY)

CONNECTOR X-067 - Engine connector CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-046 Instrument cluster X-067 Engine connector

CB-1073D (VT)

K-019 CORNER LIGHTS (A) X-067 Engine connector

CB-1035A (WH)

X-046 Instrument cluster X-067 Engine connector

CB-376 (VT)

6 7 8

CB-39A (GN)

X-031 Lights control X-067 Engine connector X-067 Engine connector X-046 Instrument cluster

CB-2041A (VT)

X-022 FUSES BOX X-067 Engine connector

10 11 12

CB-1022E (BR)

SP-1022A X-067 Engine connector

CB-1001B (WH)

SP-1001A X-067 Engine connector

CB-2015A (WH)

X-067 Engine connector X-046 Instrument cluster

CB-1001C (WH)

SP-1001A X-067 Engine connector

CB-1030G (BL)

K-005 DIP BEAM (V) X-067 Engine connector

CB-1006A (BR)

X-046 Instrument cluster X-067 Engine connector

CB-1022F (BR)

SP-1022A X-067 Engine connector

CB-1027G (BL)

SP-1026 X-067 Engine connector

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Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical schema – Sheet 05 (55.100)

Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (55.100)

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Engine components – Sheet 08 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100) Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (55.100) Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100) Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (55.100)

Electrical systems - Harnesses and connectors

84284807

CONNECTOR X-069 - RH Frontlamp PIN WIRE NUMBER NUMBER 1 CB-057AP (BK)

CONNECTOR X-069 - RH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-069 RH Frontlamp SP-057B

87705127

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Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 07 TL60E TL75E TL85E TL85E TL95E

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA LA ---

CONNECTOR X-070 - RH Frontlamp PIN WIRE NUMBER NUMBER 1 CB-49C (GN)

CONNECTOR X-070 - RH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-049A X-070 RH Frontlamp

87705127

Wiring harnesses - Electrical schema – Sheet 05 (55.100)

CONNECTOR X-071 - RH Frontlamp PIN WIRE NUMBER NUMBER 1 CB-1013H (RD)

CONNECTOR X-071 - RH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1013F X-071 RH Frontlamp

87705127

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-072 - LH Frontlamp PIN WIRE NUMBER NUMBER 1 CB-057AN (BK)

CONNECTOR X-072 - LH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-072 LH Frontlamp SP-057B

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Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100)

Electrical systems - Harnesses and connectors

87705127

CONNECTOR X-073 - LH Frontlamp CONNECTOR X-073 - LH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 1 CB-50B (GN)

SP-050A X-073 LH Frontlamp

87705127

Wiring harnesses - Electrical schema – Sheet 05 (55.100)

CONNECTOR X-074 - LH Frontlamp PIN WIRE NUMBER NUMBER 1 CB-1014H (RD)

CONNECTOR X-074 - LH Frontlamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1024A X-074 LH Frontlamp

87705127

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-075 - RH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-057AQ (BK)

CONNECTOR X-075 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-075 RH Rear Lamp SP-057B

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Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100)

Electrical systems - Harnesses and connectors

87705127

CONNECTOR X-076 - RH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-49B (GN)

CONNECTOR X-076 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-3004 X-076 RH Rear Lamp

87705127

Wiring harnesses - Electrical schema – Sheet 05 (55.100)

CONNECTOR X-077 - RH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-830 (BL)

CONNECTOR X-077 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-810 X-077 RH Rear Lamp

87705127

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-078 - RH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-1013A (RD)

CONNECTOR X-078 - RH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1013F X-078 RH Rear Lamp

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

Electrical systems - Harnesses and connectors

87705127

CONNECTOR X-079 - LH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-057AO (BK)

CONNECTOR X-079 - LH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-079 LH Rear Lamp SP-057B

87705127

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Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (55.100)

Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 08 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA ---

CONNECTOR X-080 - LH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-50D (GN)

CONNECTOR X-080 - LH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-3005 X-080 LH Rear Lamp

87705127

Wiring harnesses - Electrical schema – Sheet 05 (55.100)

CONNECTOR X-081 - LH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-820 (RD)

CONNECTOR X-081 - LH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-810 X-081 LH Rear Lamp

87705127

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

CONNECTOR X-082 - LH Rear Lamp PIN WIRE NUMBER NUMBER 1 CB-1014A (RD)

CONNECTOR X-082 - LH Rear Lamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1024A X-082 LH Rear Lamp

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Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

Electrical systems - Harnesses and connectors

87705127

CONNECTOR X-085 - Rear PTO Switch PIN WIRE NUMBER NUMBER T CB-2042E (OR)

CONNECTOR X-085 - Rear PTO Switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-085 Rear PTO Switch SP-2042E

82944111

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

CONNECTOR X-086 - Rear PTO Switch PIN WIRE NUMBER NUMBER T CB-2042F (OR)

CONNECTOR X-086 - Rear PTO Switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-086 Rear PTO Switch K-017 PTO (F)

82944111

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (55.100)

CONNECTOR X-087 - Rear PTO Switch PIN WIRE NUMBER NUMBER + CB-2042D (OR)

CONNECTOR X-087 - Rear PTO Switch CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-022 FUSES BOX X-087 Rear PTO Wiring harnesses - Electrical schema – Main wire harness Switch of the header – Relay and fuse compartment – Sheet 01 (55.100) 47835583 21/10/2015

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Electrical systems - Harnesses and connectors

82944111

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 09 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

CONNECTOR X-091 - LH Worklamp PIN WIRE NUMBER NUMBER A HO-1073A (VT)

HO-057BV (BK)

CONNECTOR X-091 - LH Worklamp CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1073 X-091 LH Worklamp

X-091 LH Worklamp SP-057AK

82003123

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

CONNECTOR X-092 - Worklamp RH PIN WIRE NUMBER NUMBER A HO-1073B (VT)

HO-057BU (BK)

CONNECTOR X-092 - Worklamp RH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-1073 X-092 Worklamp RH

X-092 Worklamp RH SP-057AK

82003123

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

CONNECTOR X-094 - Headlamp RH PIN WIRE NUMBER NUMBER 1 HO-057BR (BK)

CONNECTOR X-094 - Headlamp RH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-057BK X-094 Headlamp RH

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Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-094 - Headlamp RH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME

PIN WIRE NUMBER NUMBER 3 HO-1027A (BL)

SP-1027 X-094 Headlamp RH

HO-1030A (BL)

SP-1030 X-094 Headlamp RH

87745334

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

CONNECTOR X-095 - Headlamp LH PIN WIRE NUMBER NUMBER 1 HO-057BS (BK)

CONNECTOR X-095 - Headlamp LH CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME SP-057BK X-095 Headlamp LH

2 3

HO-1027B (BL)

SP-1027 X-095 Headlamp LH

HO-1030B (BL)

SP-1030 X-095 Headlamp LH

87745334

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

CONNECTOR X-096 - Engine Harness PIN WIRE NUMBER NUMBER 1 2 HO-1073 (VT)

HO-057BT (BK)

CONNECTOR X-096 - Engine Harness CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-096 Engine Harness SP-1073

SP-057BK X-096 Engine Harness

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Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100) Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (55.100)

Electrical systems - Harnesses and connectors

PIN WIRE NUMBER NUMBER 4 HO-057BX (BK)

CONNECTOR X-096 - Engine Harness CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-096 Engine Harness SP-057AK

HO-1030C (BL)

SP-1030 X-096 Engine Harness

HO-1027V (BL)

SP-1027 X-096 Engine Harness

84155471

CONNECTOR X-096F - Front headlamps connection CONNECTOR X-096F - Front headlamps connection PIN WIRE NUMBER CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME NUMBER 1 2 X-006 Engine connector X-096F Wiring harnesses - Electrical EN-1073C (VT) Front headlamps connection schema – Engine components – Sheet 08 (55.100) 3 X-096F Front headlamps connection Wiring harnesses - Electrical EN-057BN (BK) SP-057BN schema – Roof lights – Sheet 09 (55.100) 4 X-096F Front headlamps connection Wiring harnesses - Electrical EN-057BO (BK) SP-057BN schema – Roof lights – Sheet 09 (55.100) 5 X-006 Engine connector X-096F Wiring harnesses - Electrical EN-1030D (BL) Front headlamps connection schema – Engine components – Sheet 08 (55.100) 6 X-006 Engine connector X-096F Wiring harnesses - Electrical EN-1027T (BL) Front headlamps connection schema – Roof lights – Sheet 09 (55.100)

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Electrical systems - Harnesses and connectors

87543123

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 10 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

LA ---

CONNECTOR X-100 - Front Worklamp SW 2 PIN WIRE NUMBER NUMBER 1 CB-057AD (BK)

CB-1097D (RD)

CONNECTOR X-100 - Front Worklamp SW 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-100 Front Worklamp SW 2 SP-057BB SP-1097A X-100 Front Worklamp SW 2

84131048

Wiring harnesses - Electrical schema – Ground points – Sheet 13 (55.100) Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

CONNECTOR X-105A - Reverse Alarm 1 PIN WIRE NUMBER NUMBER 1 CB-057AL (BK)

CONNECTOR X-105A - Reverse Alarm 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-105A Reverse Alarm 1 SP-057B

84153167

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Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (55.100)

Electrical systems - Harnesses and connectors

CONNECTOR X-105B - Reverse Alarm 2 PIN WIRE NUMBER NUMBER 1 CB-1160G (RD)

CONNECTOR X-105B - Reverse Alarm 2 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME Wiring harnesses - Electrical X-028 Transmission system connection X-105B Reverse Alarm 2 schema – Transmission components – Sheet 10 (55.100)

84153167

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Electrical systems - Harnesses and connectors

Wire connectors - Component diagram 11 TL60E TL75E TL85E TL85E TL95E

LA LA ---

Without cab, 12x4, 4WD [ZDCL05524 - ] Without cab, 2WD, 12x4 [ZDCY12367 - ] Without cab, 2WD [ZEC134399 - ] Without cab, 4WD [ZDCL04468 - ] Without cab, 4WD [ZDC112512 - ]

CONNECTOR X-112 - Ground - Busbar 1 PIN WIRE NUMBER NUMBER 1 CB-057AS (BK)

CONNECTOR X-112 - Ground - Busbar 1 CIRCUIT REFERENCE ELECTRICAL SCHEMATIC FRAME X-112 Ground - Busbar 1 SP-057BC Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (55.100)

87675193

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Electrical systems - Harnesses and connectors

Electrical components - ECU description LA LA LA LA LA LA

A-001 - REAR WASHER SWITCH (ECU) Component Type Wiring frames Connectors

ECU SHEET 18 X-121 (Female) X-122 (Female)

A-005 - 4WD SW (ECU) Component Type Wiring frames Connectors

ECU SHEET 16 X-063 (Female) X-062 (Female)

A-021 - WORKLAMP SWITCH (ECU) Component Type Wiring frames Connectors

ECU SHEET 14 X-020 (Female) X-022 (Female)

A-024 - FRONT WIPER/ WASHER SWITCH (ECU) Component Type Wiring frames

ECU SHEET 18

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Electrical systems - Harnesses and connectors

Electrical components - Sensor description LA LA LA LA LA LA

B-001 - WATER TEMPERATURE SENDER (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 09 X-011 (Female)

B-004 - FUEL LEVEL SENDER (Sensor) Component Type Wiring frames Connectors

Sensor SHEET 12 X-177 (Female)

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Electrical systems - Harnesses and connectors

Electrical components - Diode description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

D-001 - DIODE (Diode) Component Type Wiring frames Connectors

Diode SHEET 07 X-045 (Female)

D-004 - 4WD DIODE (Diode) Component Type Wiring frames

Diode SHEET 11

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Electrical systems - Harnesses and connectors

Electrical components - Lamp description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

E-001 - DIP/HIGH BEAM RH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-002 - DIP/HIGH BEAM LH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-005 - HOOD WORKLAMP RH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-006 - HOOD WORKLAMP LH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-008 - REVERSE LAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 12 X-132 (Female)

E-009 - REAR LAMP LH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-012 - REAR LAMP RH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-015 - FRONT SIGNAL RH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-017 - FRONT SIGNAL LH (Lamp) Component Type Wiring frames

Lamp SHEET 15

E-028 - LICENSE PLATE LAMP (Lamp) Component Type Wiring frames

Lamp SHEET 15

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Electrical components - Fuse description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

F-020 - MAIN FUSE (Fuse) Component Type Wiring frames Connectors

Fuse SHEET 10 X-098 (Female)

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Electrical components - Voltage source description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

G-001 - BATERIA (20) (Voltage source) Component Type Wiring frames

Voltage source SHEET 10

G-002 - ALTERNATOR (Voltage source) Component Type Wiring frames Connectors

Voltage source SHEET 10 X-002 (Male) X-053 (Female) X-091 (Male)

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Electrical components - Ground description LA LA LA LA LA LA

GND-001 - GROUND (Ground) Component Type Wiring frames

Ground SHEET 08 SHEET 10

GND-002 - ENGINE GROUND (Ground) Component Type Wiring frames

Ground SHEET 09

GND-003 - CAB EARTH (Ground) Component Type Wiring frames

Ground SHEET 08 SHEET 10

GND-004 - (Ground) Component Type Wiring frames

Ground SHEET 08 SHEET 09

GND-005 - (Ground) Component Type Wiring frames

Ground SHEET 18

GND-006 - SWITCHS ILLUMINATION (Ground) Component Type Wiring frames

Ground SHEET 08

GND-007 - ROOF GND 1 (Ground) Component Type Wiring frames

Ground SHEET 08

GND-008 - ROOF GND 2 (Ground) Component Type Wiring frames

Ground SHEET 08

GND-010 - (Ground) Component Type Wiring frames

Ground SHEET 13

GND-012 - (Ground) Component Type Wiring frames

Ground SHEET 13

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Electrical components - Speaker description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

H-001 - HORN (Speaker) Component Type Wiring frames Connectors

Speaker SHEET 10 X-124A (Female) X-124B (Female)

H-002 - REVERSE ALARM (Speaker) Component Type Wiring frames Connectors

Speaker SHEET 12 X-105B (Male) X-105A (Male)

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Electrical systems - Harnesses and connectors

Electrical components - Relay description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

K-004 - FLASHER UNIT (Relay) Component Type Wiring frames Connectors

Relay SHEET 16 X-050 (Female)

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Electrical components - Load description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

L-001 - A/C COMPRESSOR (Load) Component Type Wiring frames Connectors

Load SHEET 09 X-127 (Male)

L-009 - SPEAKER RH (Load) Component Type Wiring frames Connectors

Load SHEET 13 X-052 (Female) X-051 (Female)

L-010 - SPEAKER LH (Load) Component Type Wiring frames Connectors

Load SHEET 13 X-067 (Female) X-066 (Female)

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LA LA LA LA LA LA

LMP-001 - LH CORTESY LAMP (Lamp) Component Type Wiring frames

Lamp SHEET 13

LMP-010 - RH CORTESY LAMP (Lamp) Component Type Wiring frames

Lamp SHEET 13

LMP-021 - LH FRONT WORKLAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 14 X-082 (Female)

LMP-022 - RH REAR WORKLAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 14 X-079 (Female)

LMP-023 - LH REAR WORKLAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 14 X-080 (Female)

LMP-025 - RH FRONT WORKLAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 14 X-081 (Female)

LMP-027 - BEACON LAMP (Lamp) Component Type Wiring frames Connectors

Lamp SHEET 13 X-075 (Female) X-076 (Female)

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Electrical components - Motor description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

LA LA LA LA LA LA

M-001 - STARTER MOTOR (Motor) Component Type Wiring frames Connectors

Motor SHEET 10 X-001 (Female)

M-003 - FRONT WASHER (Motor) Component Type Wiring frames Connectors

Motor SHEET 18 X-119 (Female)

M-004 - REAR WASHER (Motor) Component Type Wiring frames Connectors

Motor SHEET 18 X-120 (Female)

M-005 - REAR WIPER MOTOR (Motor) Component Type Wiring frames Connectors

Motor SHEET 18 X-028 (Female)

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Electrical components - Switch description LA LA LA LA LA LA

S-001 - AIR FILTER CLOGGING (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-009 (Female) X-009A (Female)

S-002 - ENGINE OIL PRESSURE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-014 (Female)

S-003 - BRAKE LIGHT SWITCH RH (NO) (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-093 (Female) X-093A (Female)

S-004 - LIGHTS SWITCH (Switch) Component Type Wiring frames

Switch SHEET 16

S-005 - SWITCH (Switch) Component Type Wiring frames

Switch SHEET 16

CUIS15TR00242AA

S-006 - DIFF. LOCK SWITCH (Switch) Component Type Wiring frames

Switch SHEET 12

S-007 - SWITCH (Switch) Component Type Wiring frames

Switch SHEET 16

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S-008 - SWITCH (Switch) Component Type Wiring frames

Switch SHEET 16

S-009 - SWITCH (Switch) Component Type Wiring frames

Switch SHEET 16

S-010 - 4WD PRESSURE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 11 X-112B (Female) X-112A (Female)

CUIS15TR00243AA

S-011 - STARTER SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 16 X-084 (Male)

S-013 - THERMOSTARTER SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 16 X-056A (Female) X-056 (Female)

S-014 - BRAKE OIL LEVEL SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-060 (Female) X-060A (Female)

S-016 - BRAKE LIGHT SWITCH LH (NO) (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-100 (Female) X-100A (Female)

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S-020 - LH INTERIOR LAMP SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 13 X-086 (Female)

S-021 - RH INTERIOR LAMP SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 13 X-085 (Female)

S-023 - HANDBRAKE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 12 X-058 (Female)

SW-001 - DOOR SWITCH (Switch) Component Type Wiring frames

Switch SHEET 13

SW-002 - CORNER LIGHTS SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 16 X-090 (Female) X-092 (Female)

SW-003 - TURN ON SWITCH (Switch) Component Type Wiring frames

Switch SHEET 13

SW-010 - A/C PRESSURE SWITCH (Switch) Component Type Wiring frames Connectors

Switch SHEET 09 X-126 (Female)

SW-013 - HAZARD SWITCH (57) (Switch) Component Type Wiring frames

Switch SHEET 16

SW-015 - DOOR SWITCH (Switch) Component Type Wiring frames

Switch SHEET 13

SW-016 - TURN ON SWITCH (Switch) Component Type Wiring frames

Switch SHEET 13

SW-044A001 - BEACON SWITCH (Switch) Component Type Wiring frames

Switch SHEET 13

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Connectors

X-032 (Female) X-049 (Female)

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Electrical components - Solenoid description LA LA LA LA LA LA

Y-001 - THERMOSTARTER (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 09 X-012 (Female)

Y-002 - FUEL SHUT-OFF SOLENOID (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 09 X-013 (Female)

Y-003 - 4WD SOLENOID VALVE (Solenoid) Component Type Wiring frames Connectors

Solenoid SHEET 11 X-005 (Female)

CUIS15TR00241AA

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Index Electrical systems - 55 Harnesses and connectors - 100

(*)

Wiring harnesses - Electrical schematic sheet 03 SH03 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 04 SH04 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 05 SH05 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 06 SH06 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 07 SH07 - FUSEBOX (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 08 SH08 - GROUND (*) . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 09 SH09 - ENGINE COMPONENTS (*) . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 10 SH10 - ENGINE COMPONENTS (*) . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 11 SH11 - TRANSMISSION COMPONENTS (*) . . .

Wiring harnesses - Electrical schematic sheet 12 SH12 - TRANSMISSION COMPONENTS (*) . .

Wiring harnesses - Electrical schematic sheet 13 SH13 - INTERIOR LAMPS / BEACON / RADIO (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 14 SH14 - WORKLAMPS (*) . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 15 SH15 - LIGHTS (*) . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 16 SH16 - SWITCHS (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 17 SH17 - INSTRUMENT CLUSTER (*) . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (*) . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Main wire harness – Relay and fuse compartment – Sheet 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema Main wire harness of the header – Splices – Sheet 03 (*) . .

Wiring harnesses - Electrical schema Main wire harness of the header – Switches – Sheet 04 (*) .

Wiring harnesses - Electrical schema – Sheet 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Front lights, rear lights and license plate light – Sheet 06 (*)

Wiring harnesses - Electrical schema – Switches for the auxiliary front wheel drive and work lights – Sheet 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Engine components – Sheet 08 (*) . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Roof lights – Sheet 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Transmission components – Sheet 10 (*) . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Trailer components – Sheet 11 (*) . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – instrument panel – Sheet 12 (*) . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Ground points – Sheet 13 (*) . . . . . . . . . . . . . . . . . . . . . . . . .

Electrical components - Diode description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

173

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(*)

Electrical components - ECU description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

171

Electrical components - Fuse description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

175

Electrical components - Ground description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

177

Electrical components - Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

174

Electrical components - Lamp description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

181

Electrical components - Load description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180

Electrical components - Motor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

182

Electrical components - Relay description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

179

Electrical components - Sensor description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

172

Electrical components - Solenoid description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

187

Electrical components - Speaker description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

178

Electrical components - Switch description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

183

Electrical components - Voltage source description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

176

Wire connectors - Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

116

Wire connectors - Component diagram 00 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wire connectors - Component diagram 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

127

Wire connectors - Component diagram 02 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

132

Wire connectors - Component diagram 03 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

138

Wire connectors - Component diagram 04 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

144

Wire connectors - Component diagram 05 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

149

Wire connectors - Component diagram 06 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

152

Wire connectors - Component diagram 07 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

157

Wire connectors - Component diagram 08 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

161

Wire connectors - Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

100

Wire connectors - Component diagram 09 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

164

Wire connectors - Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

104

Wire connectors - Component diagram 10 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

168

Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

107

Wire connectors - Component diagram 11 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

170

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Wire connectors - Component diagram 12 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

109

Wire connectors - Component diagram 13 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

113

Wire connectors - Component diagram 17 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114

Wire connectors - Electrical schema index - Model without cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

115

Wire connectors - Electrical schema index - Model with cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema – Main wire harness of the header – Relay and fuse compartment – Sheet 01 (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema index - Model with cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schema index - Model without cab (*) . . . . . . . . . . . . . . . . . . . . . . . . . . .

Wiring harnesses - Electrical schematic sheet 02 SH02 - DIAGRAM LEGEND (*) . . . . . . . . . . . . . .

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Electrical systems - 55 Engine starting system - 201

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Contents Electrical systems - 55 Engine starting system - 201

TECHNICAL DATA Engine starter General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Engine starting system Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Engine starter Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Engine starter Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Test â&#x20AC;&#x201C; Bench tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

DIAGNOSTIC Engine starter Engine starter - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

(*) See content for specific models 47835583 21/10/2015

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Electrical systems - Engine starting system

Engine starter - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Characteristics Power Nominal voltage Rotation (viewed from the operator's position) Minimum length of brushes Minimum diameter of manifold Maximum axial play of armature shaft Number of pinion teeth Number of poles Pinion stroke

TL60E 2.7 kW 12 V

TL75E

TL85E 3.0 kW 12 V

TL95E

Clock Wise --

70 mm 42.5 mm 0.4 mm

10 4 18 mm

9 -

Starter motor test without load Voltage Chain Starter motor rotation Duration of test

TL60E -

TL75E

TL85E 11.7 V 110 A 6700 RPM 6s

TL95E

TL60E -

TL75E

TL85E 10.1 V 670 A 1300 RPM 4s

TL95E

TL60E

TL75E

TL85E

TL95E

Starter motor test with load Voltage Chain Starter motor rotation Duration of test Diff. Winding resistance at 20 °C – Pull-in winding Winding resistance at 20 °C – Hold-in winding Current consumption at 12 V – Pull-in + hold-in – instantaneous (max.) Current consumption at 12 V – Hold-in continuous (max.)

0.24 Ω

1.05 Ω

60 A

12 A

10 A

Engine starter - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E

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TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Component Starter motor to block fixing bolts Nut for terminal 30 Solenoid cable nuts Starter motor cover nuts Solenoid fixing bolts

Torque value 34 N·m (25.1 lb ft) 24.0 - 32.0 N·m (17.7 - 23.6 lb ft) 7 N·m (5.2 lb ft) 10 N·m (7.4 lb ft) 5 N·m (3.7 lb ft)

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Electrical systems - Engine starting system

Engine starting system - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Starter system operation The starter system installed in the mechanical transmission features several basic components, namely: key-actuated starter switch, safety switches installed on the clutch pedal and power take-off drive lever, heavy duty cables, starter motor, solenoid and one start relay. The starter motor is a four-pole, four-brush type motor with integrated solenoid assembly and positively engaged transmission. The integrated solenoid incorporates two armatures connected in parallel. One armature constitutes the low resistance coil for “pulling” and is grounded through the motor. The other armature constitutes the high resistance coil for “holding” and is grounded through the solenoid body. When you perform the starting procedure (apply the clutch pedal and keep the power take-off lever in the off position) and activate the starter switch, the solenoid coils are activated and the piston is magnetically attracted to the solenoid core. This movement, which is transmitted through an articulated mechanism, forces the drive pinion to engage in the flywheel rack. When the drive pinion touches the flywheel rack, the solenoid plunger acts to close a group of contacts, which in turn supply energy direct from the battery to the four field coils that deliver all the power to the starter motor. At this point, one end of the “pulling” coil connects to the battery positive through the starter switch, while the other end is connected to the positive through the solenoid contacts. The “pulling” coil this way is deviated from the circuit and does not receive any current, while the holding coil maintains the solenoid piston engaged. The starter motor incorporates a set of single contacts and a two-part solenoid piston that close the contacts completely even if the sprocket and the pinion teeth are misaligned. When this happens the engagement spring is compressed which forces the pinion to engage completely as soon as the starter motor starts to turn. When the starter key switch is released, the current to the solenoid and starter motor is turned off. The solenoid return spring acts through the articulation mechanism and disengages the pinion gears and reopens the solenoid contacts. The drive pinion assembly incorporates a roller clutch. This clutch prevents the armature from turning excessively if the drive pinion remains engaged in the rack after the engine starts.

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Engine starter - Exploded view TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

CUIL13TR00773AA

Reference (1) (2) (3) (4) (5) (6) (7) (8) (9) (10) (11) (12) (13) (14)

Component Ring Nut Spacer Screw Brush support Cover Screw Bushing Brush Spring Armature Ring Paste Ring

Reference (15) (16) (17) (18) (19) (20) (21) (22) (23) (24) (25) (26) (27) (28)

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Component Ring Fixing bolt Armature shaft Drive Pinion Assembly Central support plate Winding Washer Nut Lever Screw Bushing Coverage Screw Diff.

Electrical systems - Engine starting system

Engine starter - Test TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Testing the starting system on the tractor For quicker and easier diagnosis and to obtain a majority of conclusive trials, we recommend you use a device to check the batteries/starter motors (quick discharge verifier) which incorporates a 0 - 20 V voltmeter and a 0 - 500 A ammeter. When using the test equipment, always follow the manufacturer's recommendations. When no test equipment is available, use a 0 - 20 V voltmeter and a 0 - 500 A ammeter and follow the procedures below to determine the correct operation of the starter motor without removing it from the engine. Before tests: • Check whether the battery is fully charged. • Check all wires in the starter system circuit for split, frayed wires or loose connections. • Make sure the motor is not locked.

Demand for current from the starter motor circuit 1. Disconnect the cable from the negative terminal of the battery (3). 2. Disconnect the battery wire on the starter solenoid. Connect the positive wire of the ammeter (1) to the positive terminal of the battery and the negative wire to the solenoid input terminal. 3. Connect the cable to the negative terminal of the battery. 4. Connect the volt meter positive wire (2) to the battery positive terminal and the negative wire to the battery negative terminal. LAIL11TL0157A0A

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Electrical systems - Engine starting system

5. Disconnect the solenoid wire (1) from the injection pump. 6. Ask someone to crank the starter motor. Observe the voltmeter and ammeter readings: • The voltage on the voltmeter must remain stable at 12 V. • The current on the ammeter must be between 250 300 A. 7. With the values obtained, do the following: • If the current demand is within specifications, the starter motor is working correctly.

CUIL13TR00807AA

LAIL11TL0158A0A

• If there is a voltage drop during the test, see the procedures indicated below. • If the demand for current is higher than that specified, check the circuit as specified below. If the starter system circuit tests do not prove satisfactory, then the starter motor is damaged and should be disassembled to determine the causes. • If the demand for current is lower than that specified, the starter motor is damaged and must be disassembled to determine the causes.

Starter system circuit resistance (Voltage drop) If there is an excessive demand for current, the circuit must be checked noting the voltage drops in each circuit component. NOTICE: Disconnect the wire (1) of the shut-off solenoid for the fuel injection pump.

Battery positive wire 1. Connect the voltmeter positive wire to the battery positive terminal. 2. Connect the negative wire of the voltmeter to the starter motor solenoid battery terminal. 3. Ask someone to crank the starter motor. Observe the readings on the voltmeter: • If it is higher than 0.2 V, check and tighten the wire connections. Check the voltage again. If it is still excessive, install new cables.

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Electrical systems - Engine starting system

Ground wiring for the starter motor (Negative) 1. Connect the positive wire of the voltmeter to the housing of the starter motor. 2. Connect the voltmeter negative wire to the engine block. 3. Ask someone to crank the starter motor. Observe the reading on the voltmeter: â&#x20AC;˘ If it is higher than 0.2 V, check the connections to the mass between the starter motor flange and the rear plate of the motor.

LAIL11TL0159A0A

LAIL11TL0160A0A

Connection wire from the mass to the battery: 1. Connect the voltmeter positive wire to the engine block. 2. Connect the voltmeter negative wire to the battery negative terminal. 3. Turn the starter motor and, at the same time, observe the voltage reading on the volt meter. If it is higher than 0.2 V, check and tighten the wire connections to the mass. Check the voltage again, if it is still excessive, assemble new cables.

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Electrical systems - Engine starting system

Engine starter - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Disconnect the cable from the negative terminal of the battery. 2. Remove the bolt (1). Remove the guard plate (2). 3. Remove the positive cable (5) and the clamp for the emergency switch (4). 4. Remove the bolts (6). Remove the starter motor from the machine.

LAIL11TL0161A0A

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Electrical systems - Engine starting system

Starter motor test with no load NOTE: To run this test, you will need a fully charged battery and a battery tester (to check rapid discharge) with a carbon disc rheostat (variable load resistance). 1. Secure the starter motor in a vise. 2. Connect the battery negative cable (4) to the starter motor assembly flange. 3. Make a bridge using a short wire (6) between the terminal on the battery solenoid and the terminal on the solenoid breaker. 4. Connect the positive wire of the voltmeter (3) to the battery's positive terminal and its negative wire to the battery's negative terminal, the positive wire (1) of the ammeter to the battery's positive terminal and its negative wire to the starter motor terminal or to the terminal on the solenoid that will connect to the battery. 5. Secure a manual revolution counter (5) to the point of the armature shaft. Activate the starter motor, adjusting the carbon pile rheostat (2) to give 11.7 V. When the armature's rotation speed is between 6700 RPM, the maximum current demand should not exceed 110 A. 6. If the starter motor does not work as specified, check whether there are holes in the induction coils, the armature is touching somewhere or the shaft is warped.

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LAIL11TL0162A0A

Electrical systems - Engine starting system

Engine starter - Disassemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

See the exploded view of the starter motor in Engine starter - Exploded view (55.201). 1. Secure the starter motor in a vise. 2. Disconnect the thick plaited cable from the field coil covering to the solenoid. 3. Remove the three bolts from of the covering and disassemble the solenoid. The piston remains on the command engage lever. 4. Separate the solenoid piston from the command lever by holding the piston and lifting its front end to remove it from the command lever. 5. Remove the two nuts and bolts which fasten the brush cover and plate on the covering. Remove clamp â&#x20AC;&#x2DC;Câ&#x20AC;&#x2122; and the armature shaft clearance bushings and remove the covering, leaving the brushes on the manifold. Remove the soft metal washer from the armature from the manifold side. 6. At this stage, inspect the brushes and manifold. Check if the brushes are bonded and, if necessary, clean the brushes and their supports using a cloth dampened with gasoline. Check the brushes for wear. If worn beyond the minimum specified length of 7.00 mm, you must replace the starter motor. NOTE: The brushes cannot be obtained separately as spare parts. They are spot welded in place and should not be replaced throughout the useful life of the starter motor. 7. Remove the housing by separating it from the armature and support on the drive side. 8. Remove the engage lever articulation pin out through the drive side of the covering. 9. Remove the drive assembly and the retaining ring from the inside plate out of the armature shaft, extracting the drive collar and fixing outside the retaining ring with a tube of adequate diameter, and then remove the retaining ring from its groove. 10. Extract the armature and drive unit.

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Electrical systems - Engine starting system

Engine starter - Test â&#x20AC;&#x201C; Bench tests TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Armature 1. Clean the manifold surface and, if necessary, eliminate the burnt points. 2. If the manifold needs rectifying, make sure its diameter is not below the minimum specified value of 42.5 mm. 3. After rectification, polish the manifold with a very fine emery cloth and then clean with a cloth dampened with petrol. NOTE: Do not cut the manifold metal when cutting out the isolating grooves. 4. Armature insulation can be checked by connecting an ohmmeter between the manifold segments and the armature shaft. The reading must be infinite, that is, no continuity.

LAIL11TL0164A0A

LAIL11TL0163A0A

5. To check for short circuit on the armature, suitable equipment will be needed for performing tests on the armature or, alternatively, this can be checked through replacement. 6. If there is evidence that the armature circumference has been in contact with the polar masses, it is likely that the armature bearings are excessively worn. 7. First check if the polar masses are well tightened and if the armature turns freely on a vise. Done that and if necessary, replace the armature bearings.

Induction coils 1. To test the insulation of the induction coils, connect an ohmmeter between each of the brushes and any part of the case that is clean and paint-free. There should no continuity. 2. To test the insulation of the inductor spools, connect an ohmmeter between each of the brushes and the main power supply terminal (thick twisted wire). There should be a 1 Mâ&#x201E;Ś reading. 3. If there is damage to the inductor spools the complete inductor coils and the covering assembly must be replaced.

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Electrical systems - Engine starting system

Bearings 1. Examine the bearings on the brush cover and the covering on the drive side for wear. Assemble the armature shaft and check the clearance by replacing the bearings if the clearance seems excessive. Check the polar masses for signs of friction with the armature, which could also have been caused by worn brushes.

Driving pinion 1. Check the operation of the roller clutch. The pinion should only turn clockwise. If the pinion is stuck, turn it in both directions, or if the teeth are damaged, assemble a new drive assembly. If the drive pinion teeth are clearly damaged, also check the engine flywheel rack teeth.

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Electrical systems - Engine starting system

Engine starter - Backlash TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Checking the longitudinal clearance of the armature 1. Secure the starter motor in a vise. Mount a calibration gauge on the flange of the cover on the drive side. Place the gauge point on the end of the armature shaft. 2. Move the armature fully forward and set the gauge to zero. Move the shaft completely backward and record the calibration gauge reading. 3. The reading must not exceed 0.4 mm. If the reading exceeds this value, inspect the armature and the brush cover for wear. Replace the worn components and check the longitudinal clearance again.

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Electrical systems - Engine starting system

Engine starter - Assemble TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Prior operation: Engine starter - Backlash (55.201) 1. Perform the alternator test with no load before assembly. Consult the procedures in Engine starter - Test (55.201). 2. To install the alternator, follow the removal procedure in reverse order. Consult the procedures in Engine starter - Disassemble (55.201).

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Electrical systems - Engine starting system

Engine starter - Troubleshooting Problem Possible Cause Operation failed. There is Open field coil circuit no current flow Open armature circuit Defective commutator and brush contact

Operation failed. Excessive current flow. Idle speed. Low current flow High speed. Excessive current flow The solenoid engages, but the shaft does not rotate

Correction Replace the stator assembly

Open solenoid circuit Defective solenoid contacts Grounded armature or field coil

Replace armature Clean the brush holder. Replace the brushes and brush holder set Replace solenoid Replace solenoid Replace the starter motor

Seized bearing High internal resistance.

Replace the starter motor Replace the starter motor

Defective commutator and brush contact

Clean the brush holder. Replace the brush set and brush holder set. Replace the starter motor

Short-circuited field coil. Broken or worn brushes

Short-circuited field coil The solenoid engages and Short-circuited solenoid hold-in circuit disengages quickly Damaged impeller The starter motor operates, but the engine does not start. Pinion will not engage in the flywheel of the machine

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Clean the brush holder. Replace the brush set and brush holder set Replace the starter motor Replace solenoid Replace the starter motor Replace the starter motor

Index Electrical systems - 55 Engine starting system - 201

(*)

Engine starter - Assemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Backlash (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Disassemble (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Exploded view (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Test â&#x20AC;&#x201C; Bench tests (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Test (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starter - Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Engine starting system - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Alternator - 301

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Contents Electrical systems - 55 Alternator - 301

TECHNICAL DATA Alternator General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Alternator Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

SERVICE Alternator Electrical test – Continuity of the wiring to the alternator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Electrical test – Charging current and controlled voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Electrical test – Drop in voltage and charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Electrical test - Alternator maximum output performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Electrical test – Testing the rotor field circuit and voltage regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Alternator drive system Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

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Electrical systems - Alternator

Alternator - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Polarity Nominal voltage Maximum rotation Maximum current at 6000 RPM Regulator controlled voltage Rotor field spool resistance Stator field spool resistance Length of new brushes Minimum brush length Brush spring pressure

Alternator type 85 A — Models without cab 120 A — Cab models Earthed negative pole Earthed negative pole 12 V 14 V 15000 RPM 18000 RPM 85 A 120 A 13.6 - 14.4 V 13.6 - 14.4 V 2.9 Ω 2.6 Ω 0.2 Ω 0.075 Ω 20 mm 20 mm 5 mm 5 mm 1.3 - 2.7 N·m 1.3 - 2.7 N·m

Alternator - Torque TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Torque 43 - 56 N·m

Component Tensioner fixing bolt Upper nut for fixing the alternator to the tensioner Nut for the lower fixing flange bolt of the alternator Nut for fixing the pulley to the alternator Rectifier fixing bolts Voltage regulator and brush box bolts Nut for terminal W Nut for terminal B+

43 - 56 N·m 75 - 98 N·m 75 - 105 N·m 4.0 N·m 2.7 N·m 2.7 - 3.8 N·m 4.2 - 6 N·m

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Alternator - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

The alternator is installed in the front part of the engine and is activated by the crankshaft pulley by a belt. The alternator has an integrated electronic tension regulator. Figure 1: Platform models – 85 A alternator.

LAIL11TL0165A0A

LAIL11TL0166A0A

Figure 2: Cab models – 120 A alternator. 1. Connection to earth (Ground) 2. Connection of engine speed sensor (Terminal W) 3. Warning light (Terminal D+) 4. Output connection (Terminal B+) 5. Terminal protection sleeve

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Electrical systems - Alternator

Alternator operation The alternator (1) performs battery charging and battery charging maintenance. It generates current to power the machine's electrical components.

CUIL13TR00771AA

When the starter switch/ignition key is switched on, there is a low value current that leaves the batter and passes through the rotor field spool. The circuit is established through the warning light that indicates the charge at alternator terminal 'D+', at the rotor field spool, at the alternator voltage regulator and at the ground. In this phase the warning light turns on and the rotor is partially magnetized. When the engine starts and the partially magnetized rotor starts spinning between the stator spools, a three phase current is generated. A constant amount of the generated current is converted into continuous current by the three field diodes incorporated within the rectifier set. This continuous current returns to complement the current passing through the rotor field spool. The result of this action is a continually increasing magnetic induction of the rotor, associated with a rapid rise in the supply of current and voltage. During the increase in the voltage supplied (available in terminal 'D+') the warning light dims and when the tension at terminal 'D+' equals the voltage on the side of the battery, the warning light goes out. The voltage continues to increase until the pre-set regulated voltage level is reached. Should the belt break, voltage will not be generated in the alternator and a warning light will appear on the control panel indicating a fault in the system.

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Electrical systems - Alternator

Alternator - Sectional view 120 A alternator

CUIL13TR00798AA

Reference (1) (2) (3) (4) (5) (6) (7)

Component Nuts and studs for closing the alternator (housing union) Rear cover Manifolds and brushes Rotor shaft Rotor Rectifiers Rear support

Reference

Component

(8)

Internal fan

(9) (10) (11) (12) (13) (14)

Stator Front bearing Pulley nut Pulley Bolt and guard for the front bearing Tensioner support

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Alternator - Electrical test â&#x20AC;&#x201C; Continuity of the wiring to the alternator 1. Disconnect the negative (-) cable from the battery. 2. Disconnect alternator terminals B+ (2) and D+ (3). 3. Connect the cable to the negative terminal of the battery. 4. Turn the ignition key to the on position but without starting the engine. Connect the voltmeter (4) between each terminal and the earth (ground) (1). 5. There should be voltage on the battery. If there is not, there is a continuity failure in the external circuit cables which must be located and repaired. 6. Connect terminal D+, wire to earth (ground). The warning light should come on. NOTE: If the warning light fails to come on when the cable is reconnected to the alternator, this indicates that there is a fault in the regulator or alternator rotor circuits. Check that terminal D+ is clean. Then carry out testing of the alternator components, as detailed in Alternator - Electrical test â&#x20AC;&#x201C; Testing the rotor field circuit and voltage regulator (55.301). 7. Disconnect the cable from the negative terminal of the battery. 8. Reconnect the wiring to the alternator. 9. Connect the cable to the negative terminal of the battery.

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LAIL11TL0170A0A

Electrical systems - Alternator

Alternator - Electrical test – Charging current and controlled voltage 1. Check that the tractor electrical components are switched off and that the ignition key is in the off position. 2. Disconnect the cable from the negative terminal of the battery. Disconnect the terminal B+ (4) from the alternator. 3. Connect an ammeter (1) between the removed cable (3) and the B+ terminal (4). 4. Connect a voltmeter (2) between the terminal B+ (4) and the earth (ground). 5. Connect the cable to the negative terminal of the battery. Run the engine between 2000 RPM. Take readings from the ammeter and from the voltmeter. • The voltmeter should indicate a value above that of the battery voltage and, when the ammeter reading is below 10 A the voltmeter reading should stabilize between 13.6 - 14.4 V. • If the voltmeter reading exceeds 14.4 V, you must replace the alternator regulator. • If the voltmeter reading is below 13.6 V this indicates that there is a damaged alternator component or a fault due to high resistance on the recharge system external connections. • If the ammeter indicates 0 A, this means that there is a defective alternator component. Shut down the engine and perform the "alternator component tests," as indicated in Alternator - Electrical test – Testing the rotor field circuit and voltage regulator (55.301).

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LAIL11TL0171A0A

Electrical systems - Alternator

Alternator - Electrical test – Drop in voltage and charging circuit Drop in voltage on the insulated side 1. Check that the ignition key is in the off position. 2. Disconnect the negative battery cable and disconnect the alternator B+ cable (1). 3. Connect a millivolt meter (4) between the positive battery terminal and cable B+ (5). (connect the cable to the positive side). 4. Connect an ammeter (2) between the alternator terminal B+ and the cable B+. Connect the cable to the negative side. 5. Connect the cable to the negative terminal of the battery. LAIL11TL0172A0A

LAIL11TL0173A0A

6. Connect a potentiometer (3) with the cursor on the minimum current passage (maximum resistance) between the battery terminals. 7. Start the engine and adjust its rotation to 2000 RPM. 8. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 85 A or 120 A, according to the respective model being tested. 9. Check the voltmeter reading. value: 400 mV.

Maximum expected

• If the reading is over 400 mV, there is a high resistance defect in the external circuit. • If the expected alternator value cannot be reached and the millivoltmeter reading is below 400 mV, this means there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test – Testing the rotor field circuit and voltage regulator (55.301). 10. Stop the engine.

Drop in voltage on the ground side 1. Check that the ignition key is in the off position. 2. The circuit is the same circuit used in the previous test. However, now the millivoltmeter (4) is connected between the negative terminal and the housing of the alternator. NOTE: Check whether the potentiometer (3) is regulated for the passage of minimum current (maximum resistance). 3. Start the engine and adjust its rotation to 2000 RPM. 4. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 85 A or 120 A, according to the respective model being tested.

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Electrical systems - Alternator

5. Check the voltmeter reading. value: 200 mV

Maximum expected

â&#x20AC;˘ If the reading is over 200 mV, there is a high resistance defect in the external circuit. â&#x20AC;˘ If the expected alternator value cannot be reached and the millivoltmeter reading is below 200 mV, this means there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test â&#x20AC;&#x201C; Testing the rotor field circuit and voltage regulator (55.301). 6. Stop the engine.

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Electrical systems - Alternator

Alternator - Electrical test - Alternator maximum output performance 1. Check that the ignition key is in the off position. 2. Disconnect the cable from the negative terminal of the battery. Disconnect the cable B+ (5) from the alternator. 3. Connect an ammeter (2) between the alternator terminal B+ (1) and the cable B+ to the negative side. 4. Connect a voltmeter (4) between alternator terminal B+ and the earth (ground). 5. Connect the cable to the negative terminal of the battery. LAIL11TL0174A0A

6. Start the engine and adjust its rotation to 2000 RPM. 7. Slowly increase the potentiometer current charge (reduce the resistance) until the ammeter records 85 A or 120 A, according to the respective model being tested. 8. Check the voltmeter reading. The minimum expected value is 13.6 V. â&#x20AC;˘ If the reading is under 13.6 V, this means that there is a defective alternator component. Perform the alternator component tests according to the procedures described in Alternator - Electrical test â&#x20AC;&#x201C; Testing the rotor field circuit and voltage regulator (55.301).

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Alternator - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Disconnect the battery negative (-) cable (1).

CUIL13TRO0194AA

CUIL13TR00771AA

CUIL13TR00772AA

2. Disconnect all the electrical connections (2) and (3) located behind the alternator. NOTE: Identify the components to facilitate re-assembly. 3. Remove nut (1).

4. Loosen the nut (3) and position the alternator to the side of the engine to facilitate the removal of the belt (1). 5. Remove the belt (1). 6. Remove the nut (3) and remove the through bolt. 7. Remove the alternator (2).

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Alternator - Electrical test â&#x20AC;&#x201C; Testing the rotor field circuit and voltage regulator 1. Remove all the cables from the alternator. 2. Connect a 12 V battery and a 2.2 W (2) test lamp in series between the terminal D+ (1) and the alternator housing (connect to the negative side of the housing). 3. The light shall illuminate. If the light does not illuminate, this means there is a defect in the rotor circuit. Check the brushes, the slide rings and the rotor field spool continuity. 4. If the test shows that these parts are in satisfactory condition, the problem could be in the voltage regulator. LAIL11TL0175A0A

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Alternator - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Make sure that the negative cable of the battery is disconnected. 2. Position the alternator in its housing and install the through bolt. Install the nut (1) on the bolt. 3. Move the alternator to the side of the engine to enable installation of the belt on the alternator pulley.

CUIL13TR00772AA

CUIL13TR00771AA

4. Install the belt (5) on the pulleys of the alternator, of the crankshaft and of the water pump. NOTE: If the machine has air conditioning, remove the air conditioning belt to enable installation of the alternator belt. 5. Position the nut (1) in its housing. 6. Install all the electrical connections (2) and (3) located behind the alternator. 7. Adjust the tension of the alternator belt. See the procedures described in Alternator drive system Belt Tension adjust (55.301).

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Electrical systems - Alternator

Alternator drive system Belt - Tension adjust 1. Check whether the belt has a slack between 10 11 mm with a load of 8 - 10.0 kg (10 - 22.0 lb) measured between the pulleys. If the values are not within the specifications, adjust the belt as follows: 2. Loosen the lower nut (1) and the upper (2) nut. 3. Move the alternator to obtain the correct voltage in accordance with the specifications. 4. Retighten the upper nut (2) then the lower nut (1). NOTE: Replace the belt when it appears cut or it requires regular adjustments. CUIL13TR00772AA

NOTE: On machines equipped with air conditioning, two belts drive the alternator. Replace both the belts if necessary.

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Alternator drive system - Tension adjust CAUTION Avoid injury! Handle all parts carefully. Do not place your hands or fingers between parts. Use Personal Protective Equipment (PPE) as indicated in this manual, including protective goggles, gloves, and safety footwear. Failure to comply could result in minor or moderate injury. C0145A

1. Press the ball (1) so that the lower rods fit into the belt. NOTE: To obtain a uniform tension, never position the tool over the seam of the belt.

CUIS15TR00246AA

CUIS15TR00247AA

2. Keep the tool flush on the edge of the belt. Then release the ball (1) in one single movement.

3. Read the tension units on the gauge (2). 4. Adjust the belt tension in accordance with the specification. NOTE: The belt must be replaced if it shows any damage such as cuts or requires frequent adjustment. 5. Remove the tool from the belt before you start the machine. NOTE: Periodically check the calibration of the tool.

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Tool calibration procedure 1. Suspend the standard weight (1) on the lower end of the belt. 2. Install the tool on the belt. 3. The belt tension reading should be the same as the weight used for calibration. Example: 180 lb 81.65 kg.

CUIS15TR00248AA

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Index Electrical systems - 55 Alternator - 301

(*)

Alternator - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Electrical test - Alternator maximum output performance . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Electrical test – Charging current and controlled voltage . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Electrical test – Continuity of the wiring to the alternator . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Electrical test – Drop in voltage and charging circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Electrical test – Testing the rotor field circuit and voltage regulator . . . . . . . . . . . . . . . . .

Alternator - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Sectional view . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator - Torque (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator drive system - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Alternator drive system Belt - Tension adjust . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

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Electrical systems - 55 Battery - 302

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Contents Electrical systems - 55 Battery - 302

TECHNICAL DATA Battery General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

FUNCTIONAL DATA Battery Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

SERVICE Battery Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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Electrical systems - Battery

Battery - General specification TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

TL60E

TL75E

Capacity Voltage Mass Terminal

TL85E 100 AÂ·h 12 V Negative

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TL95E

Electrical systems - Battery

Battery - Dynamic description TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Description and operation All of the tractor models incorporate a 12 V battery with a grounded negative pole. NOTE: 'Without Maintenance' means that under normal conditions, the battery does not lose water from the electrolyte. There could be water loss under certain conditions, such as during a prolonged charge at over 14.4 volts, giving rise to the production of gasses when full charge is reached. 14.4 V This could be caused by a defective charging system or by the rapid charge equipment. The battery is installed in the front part of the tractor, between the engine radiator and the front counterweight support, The batteries have four main functions: • Provide a source of electrical current for starting, lights and instruments. • Help to maintain control of voltage in the electrical installation. • Supply electrical current when the demand exceeds the alternator capacity. The battery is manufactured in such a way that each element contains positive and negative plates arranged alternately one next to the other. Each positive plate is separated from the negative plate by a porous and non-conductor separator. If a positive plate makes contact with a negative plate inside the element, the element will short-circuit and be damaged beyond repair. All positive plates are welded to a bar, forming a positive terminal and the negative plates are welded to another similar bar that forms the negative terminal. Each positive plate is constituted of a lead grid with lead peroxide stuck between the grid openings. The negative plates are constituted of a grid with spongy lead stuck into the grid openings. The plates are immersed in a solution of diluted sulphuric acid liquid electrolyte.

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Electrical systems - Battery

Battery - Remove TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

1. Raise the engine hood. 2. Disconnect the negative (ground) battery cable. (3) 3. Remove the nuts (1) and (2) from the battery fixing plate and remove the plate. 4. Disconnect the positive (+) battery cable. 5. Manually lift and remove the battery from the tractor.

CUIL13TRO0194AA

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Electrical systems - Battery

Battery - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL60E TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL75E TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL85E TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ] TL95E

Perform battery installation in accordance with the disassembly procedures, but in the reverse order, taking into account the following: 1. Check that the battery is clean and dry and that all of the stoppers are in place. Lubricate the terminals using Vaseline. Do not use conventional grease as this may cause electrolytic corrosion. 2. Check that the battery installation location is clean and free of stones or objects which could damage it. 3. Clean the posts and connect them to the battery terminals, making sure that the negative terminal (-) is connected last.

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CUIL13TRO0194AA

Electrical systems - Battery

Battery - Electrical test DANGER Hazardous chemicals! Battery electrolyte contains sulfuric acid. Contact with skin and eyes could result in severe irritation and burns. Always wear splash-proof goggles and protective clothing (gloves and aprons). Wash hands after handling. Failure to comply will result in death or serious injury. D0105A

1. The machines are equipped with maintenance-free batteries. Keep the top part of the battery clean and dry. Never use the fast charge option on battery chargers when recharging the batteries. Check the charge using a digital voltmeter as follows: 2. Connect the voltmeter to the two battery terminals according to the symbols (negative with negative and positive with positive) and note down the value displayed on the voltmeter. 3. Compare the results with the values in the following table to determine the battery charge. 4. If the voltage is around 12.3 V, recharge the battery immediately with a current equal to 1/10 of the capacity in Ah (a battery of 50 AÂˇh must be charged at 5 AÂˇh).

CUIL13TRO0194AA

NOTE: If the battery needs recharging or tends to go flat, have the machine's electrical system checked by your NEW HOLLAND dealer. Voltage ( V) 12,6 12,42 12,24 12,09

Charge level 100% 75% 50% 25%

NOTE: Before recharging the battery, always disconnect the cables. The battery must be removed from the machine and recharged away from it.

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Index Electrical systems - 55 Battery - 302

(*)

Battery - Dynamic description (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Electrical test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - General specification (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Battery - Remove (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

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specific

models

Electrical systems - 55 Fuel tank system - 011

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Contents Electrical systems - 55 Fuel tank system - 011

FUNCTIONAL DATA Fuel level sensor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Fuel tank system

Fuel level sensor - Dynamic description Indicates the level of diesel fuel in the fuel tank.

CUIL13TR00809AA

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Index Electrical systems - 55 Fuel tank system - 011 Fuel level sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine intake and exhaust system - 014

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Contents Electrical systems - 55 Engine intake and exhaust system - 014

FUNCTIONAL DATA Air cleaner restriction sensor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine intake and exhaust system

Air cleaner restriction sensor - Dynamic description The sensor (1) is activated when the vacuum in the air operating system exceeds a pre-established value. The warning light on the instrument panel illuminates.

CUIL13TR00814AA

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Index Electrical systems - 55 Engine intake and exhaust system - 014 Air cleaner restriction sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine cooling system - 012

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Contents Electrical systems - 55 Engine cooling system - 012

FUNCTIONAL DATA Engine coolant temperature sensor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine cooling system

Engine coolant temperature sensor - Dynamic description The temperature transmitter resistance changes proportionally according to water temperature. It generates a modulated signal voltage that influences the gauge reading.

CUIL13TR00810AA

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Index Electrical systems - 55 Engine cooling system - 012 Engine coolant temperature sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Engine oil system - 013

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Contents Electrical systems - 55 Engine oil system - 013

FUNCTIONAL DATA Engine oil pressure sensor and switch Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Engine oil system

Engine oil pressure sensor and switch - Dynamic description Activated as soon as the engine oil pressure drops below 0.68 bar. 0.68 bar The warning light comes on. This switch is normally closed.

CUIL13TR00811AA

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Index Electrical systems - 55 Engine oil system - 013 Engine oil pressure sensor and switch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Service brake electrical system - 030

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Contents Electrical systems - 55 Service brake electrical system - 030

FUNCTIONAL DATA Brake fluid level sensor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Air pressure switch Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Electrical systems - Service brake electrical system

Brake fluid level sensor - Dynamic description The sensor (1) is activated when the brake fluid level drops below the minimum value. The warning light on the instrument panel illuminates.

CUIL13TR00815AA

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Electrical systems - Service brake electrical system

Air pressure switch - Dynamic description The switch (1) is responsible for turning on the brake lights when the service brakes are activated.

CUIL13TR00823AA

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Index Electrical systems - 55 Service brake electrical system - 030 Air pressure switch - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Brake fluid level sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Electrical systems - 55 Parking brake electrical system - 031

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Contents Electrical systems - 55 Parking brake electrical system - 031

FUNCTIONAL DATA Parking lock sensor Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Electrical systems - Parking brake electrical system

Parking lock sensor - Dynamic description The switch is normally open. When the parking brake lever is operated, the switch turns on (closes). An indicator light illuminates on the instrument panel.

CUIL13TR00819AA

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Index Electrical systems - 55 Parking brake electrical system - 031 Parking lock sensor - Dynamic description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SERVICE MANUAL Platform, cab, bodywork, and decals TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ], TL60E Without cab, 12x4, 4WD [ZDCL05524 - ], TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ], TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ], TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ], TL85E Without cab, 4WD [ZDCL04468 - ], TL85E Without cab, 2WD [ZEC134399 - ], TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ], TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ], TL95E Without cab, 4WD [ZDC112512 - ], TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ]

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Contents Platform, cab, bodywork, and decals - 90

[90.150] Cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.1 [90.110] Operator platform less cab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.2 [90.114] Operator protections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.3 [90.124] Pneumatically-adjusted operator seat. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.4 [90.100] Engine hood and panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.5 [90.102] Engine shields, hood latches, and trims . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90.6

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CONSUMABLES INDEX Consumable R134a

Reference Cab roof - Install

PAGE 90.1 / 20

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Platform, cab, bodywork, and decals - 90 Cab - 150

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Contents Platform, cab, bodywork, and decals - 90 Cab - 150

SERVICE Cab Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Cab roof Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

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CONSUMABLES INDEX Consumable R134a

Reference Cab roof - Install

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PAGE 90.1 / 20

Platform, cab, bodywork, and decals - Cab

Cab - Raise 1. With the help of a suitable lifting device, position the lift bracket 380003353 (1) above the cab. NOTE: Place protective material on the cab roof to prevent any damage.

CUIL14TR00507AA

CUIL14TR00508AA

CUIL13TR00499AA

CUIL13TR00741AA

2. Attach the front of the lift frame (1) to the handrails.

3. Attach the rear of the lift frame on the frames (1).

4. Lift the carpet on the floor and remove the two bolts (1) (one on each side) that secure the cab to its supports.

5. Remove the fuel tank. (10.216).

See Fuel tank - Remove

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Platform, cab, bodywork, and decals - Cab

6. Remove the nut (1) from the front pads of the cab. NOTE: Perform the procedure on both sides of the machine.

CUIL13TR00743AA

CUIL13TR01267AA

CUIL13TR00604AA

LAIL11TL0761A0A

7. Loosen the bolts (1) that fasten the rear of the cab to the side shaft support. Perform the procedure on both sides of the machine.

8. Loosen the breather tubes (1) and (2).

9. Remove the locks (1) and loosen the two lift lever control rods (2).

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Platform, cab, bodywork, and decals - Cab

10. Remove the Lift-O-Maticâ&#x201E;˘ (1) control rod.

LAIL11TL0762A0A

11. Loosen the connection (2) and disconnect the oil feed tube from the gearbox (1).

LAIL11TL0763A0A

LAIL11TL0766A0A

CUIL14TR00507AA

12. Lift the operator cab approximately 5 cm and place two blocks of wood (1) between the frame and the support (2).

13. Lower the cab until it is supported on the wooden blocks. Remove the lift frame 380003353 (1).

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Platform, cab, bodywork, and decals - Cab

Cab - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Remove the engine side shields. Consult the procedures in Side shield - Remove (90.102). 2. Disconnect the engine tachometer cable (1) and remove the set support bolts (2).

LAIL11TL0557A0A

LAIL11TL0558A0A

CUIL13TR01268AA

3. Remove the hood. Refer to Hood - Remove (90.100). 4. Disconnect the two hoses (1) from the steering cylinder. NOTE: Mark the hoses with their respective connections to facilitate assembly.

5. Disconnect the steering pump hose (1).

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6. Disconnect the steering return hose (1) leading to the tank.

CUIL13TR01269AA

CUIL13TR01272AA

CUIL13TR01270AA

CUIL13TR01271AA

7. Disconnect the electrical connections (1), cab wiring harness (2) and brake cylinder wiring harnesses (3).

8. Remove the brake fluid reservoir (1).

9. Disconnect the air conditioning tubes (1) and the starter motor wiring (2).

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10. Disconnect the cable from the injection pump.

LAIL11TL0560A0A

LAIL11TL0561A0A

11. Remove the indicator connections and the sidelight connections (1) on both sides of the tractor.

12. Loosen the knobs (2) and remove the guard (1) on both sides of the steering column. 13. Remove the throttle pedal cable.

LAIL11TL0580A0A

LAIL11TL0562A0A

14. Release the fixing nut and remove the clutch activation rod (1). 15. Drain the engine coolant. Consult the procedures in Radiator - Drain fluid (10.400).

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Platform, cab, bodywork, and decals - Cab

16. Loosen the bolt (1) that supports the heating tube (2).

LAIL11TL0564A0A

LAIL11TL0565A0A

LAIL11TL0571A0A

LAIL11TL0572A0A

17. Loosen the clamps (1). Disconnect the heating tubes (2) from the cab (2). NOTE: Mark the tubes with their respective connections to facilitate assembly.

18. Remove the fixing pin (1) and remove the rod for controlling the hydraulic lift (at the rear).

19. Remove the respective fixing pins and the hydraulic control rods (1). If necessary, remove the hydraulic control rods on the cab as well.

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Platform, cab, bodywork, and decals - Cab

20. Remove the breather tubes (1) and (2). 21. Disassemble the control rods from the auxiliary valves.

CUIL13TR00604AA

LAIL11TL0574A0A

LAIL11TL0575A0A

LAIL11TL0576A0A

22. Remove the springs (1) that support the synchronized Power Take-Off (PTO) control lever on the gearbox. 23. Disconnect the activation hitch lever.

24. Remove the speed selection rod of the PTO (1).

25. Remove the guard (1), the fixing bolt and the control lever from the reverser (2).

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Platform, cab, bodywork, and decals - Cab

26. Lower the guard and undo the fixing bolt. Remove the gear selection lever (1). 27. Lower the guard and undo the fixing bolt. Remove the range selection lever (2).

LAIL11TL0627A0A

LAIL11TL0577A0A

LAIL11TL0578A0A

LAIL11TL0579A0A

28. Remove the lock ring and remove the pin from the hand brake control cable. 29. Remove the hand brake cable.

30. If there is mechanical differential lock, remove the cotter pins and the front and rear articulation forks from the activation lever. 31. Remove the activation lever for the differential lock.

32. Disassemble the Lift-O-Maticâ&#x201E;˘ control cable (1) from the hydraulics cover lever and remove it from the assembly (2).

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Platform, cab, bodywork, and decals - Cab

33. Remove the cab access ladder (1).

CUIL13TR00689AA

CUIL14TR00507AA

CUIL14TR00508AA

CUIL13TR00499AA

34. With the help of a suitable lifting device, position the lift bracket 380003353 (1) above the cab. NOTE: Place protective material on the cab roof to prevent any damage.

35. Attach the front of the lift frame (1) to the handrails.

36. Attach the rear of the lift frame on the frames (1).

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37. Raise the cab slowly until the nylon ropes (1) and (2) are tensioned.

CUIL14TR00510AA

CUIL13TR01267AA

CUIL13TR00743AA

CUIL14TR00510AA

38. Loosen the bolts (1) that fasten the rear of the cab to the side shaft support. NOTE: Perform the procedure on both sides of the machine.

39. Loosen the bolt (1) that fastens the front of the cab to its support. NOTE: Perform the procedure on both sides of the machine.

40. Raise the cab slowly. Remove the cab. Place the cab on a secure stand. NOTE: While lifting the cab, make sure all cables and hoses are free from obstruction.

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Platform, cab, bodywork, and decals - Cab

Cab roof - Remove 1. Position the tractor so that the roof of the cab is beneath a suitable lifting device. 2. Disconnect the negative battery cable from the battery. 3. Apply the parking brake. 4. Remove the two front clips and the two rear clips indicated by the arrows from the side frames (1) and (2). Remove the side pillars (1) and (2).

CUIL13TR00770AA

CUIL13TR00755AA

CUIL13TR00761AA

CUIL13TR00759AA

5. Disconnect the power cables from the cigarette lighter (2) and from the courtesy light on the left-hand frame (1). 6. Disconnect all the electrical connectors from the lefthand and right-hand pillars. NOTE: Identify the electrical components to facilitate assembly.

7. Remove the bolts (1) and (3). Remove the panel for the air-conditioning controls (2).

8. Loosen the clip (1) from the heating control cable. 9. Disconnect the end of the control lever cable that is located behind the panel (2).

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Platform, cab, bodywork, and decals - Cab

10. Disconnect the cables (1) from the thermostat for the air conditioner. 11. Disconnect the fan control cables (2). NOTE: Identify the electrical components to facilitate assembly.

CUIL13TR00756AA

CUIL13TR00752AA

CUIL13TR00786AA

CUIL13TR00740AA

12. Remove all the clips on the periphery of the roof indicated by the arrows in the figure to the side. Use a suitable tool to avoid damaging the lining.

13. Remove the connector (1) for the four headlights on the cab roof. There is one connector at each corner of the roof. 14. Remove the connector (3) for the front windshield wiper motor. 15. Disconnect the washer hose (2) which is located next to the nozzle, to the side of the wiper motor. 16. Identify and remove the remaining electrical connectors on the inside of the roof. If necessary, see the wiring diagrams in Wiring harnesses - Electrical schematic sheet 18 SH18 - ROOF COMPONENTS (55.100). 17. Drain a few liters of engine coolant. 18. Identify and disconnect the hoses (3) and (4) located on the left-hand side of the evaporator box. 19. Disconnect the two drain hoses from the connections (1) and (2).

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Platform, cab, bodywork, and decals - Cab

20. Disconnect the two drain hoses (1) and (2) located on the right-hand side of the evaporator box.

CUIL13TR00777AA

21. Remove the bolts around the cover (1). Remove the cover from the cab roof. 22. Discharge and recover the refrigerant using an approved recovery system. Consult the procedures in Air conditioning - Recover (50.200).

CUIL13TR00744AA

CUIL13TR00736AA

CUIL13TR00750AA

23. Disconnect the hoses (1) and (2) from the expansion valve located on the right-hand side of the evaporator.

24. Remove the bolts (2) located on the upper bars. (1). Remove the roof (2).

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Platform, cab, bodywork, and decals - Cab

25. Make sure you have disconnected all the electrical connectors and hoses.

CUIL13TR00746AA

CUIL13TR00745AA

26. Gather up the spacer washers (1) on the cab frame. 27. Remove the seals (2) and discard. Use new seals when re-installing the roof.

Next operation: Cab roof - Install (90.150).

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Platform, cab, bodywork, and decals - Cab

Cab roof - Install 1. Install new seals (2) on the cab frame. 2. Install the spacer washers (1) in all the seal fittings.

CUIL13TR00745AA

CUIL13TR00746AA

CUIL13TR00751AA

CUIL13TR00731AA

3. With a suitable lifting device, position the roof (1) over the structure in such a way as to align the mounting points for the bolts (2), figure (3).

4. Secure the roof by installing all the bolts (2) underneath the upper bars (1).

5. Mount new seal rings (1) and (2) on the galleries of the expansion valve (3).

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Platform, cab, bodywork, and decals - Cab

6. Connect the hoses (1) and (2) on the right-hand side of the evaporator. 7. Apply a vacuum to the gas circuit and recharge with R134A gas. Use an approved recovery system. Consult the procedures in Air conditioning - Charging (50.200).

CUIL13TR00736AA

CUIL13TR00744AA

CUIL13TR00777AA

CUIL13TR00740AA

8. Fit the top cover (1) to the roof and secure the cover with the bolts.

9. Connect the drain hoses (1) and (2) on the right-hand side of the evaporator box.

10. Connect the drain hoses to the connections (3) and (4) on the left-hand side of the evaporator box. 11. Connect the hose (5) to the connection (1) for the heating control valve. 12. Connect the return hose (6) to the brass connection (2) of the heater. 13. Top up the level or replace, if necessary, the engine coolant. NOTE: When starting the engine, turn on the heating system and leave the heating system running for five minutes on the maximum heat setting. Shut down the engine and top up the level of coolant. 14. Connect the washer hose (7) to the back of the nozzle, to the side of the wiper motor.

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Platform, cab, bodywork, and decals - Cab

15. Check the condition of the grommets (2) for the power cables going to the four headlights on the cab roof. If necessary, replace the grommets. 16. Feed the cables (1) through the grommets (2).

CUIL13TR00742AA

17. Install the connectors for the four headlights. There is one connector at each inside corner of the roof. 18. Install the connector (3) for the front windshield wiper motor. 19. Install the windshield washer hose (2). 20. Install the other electrical connectors on the inside of the cab.

CUIL13TR00786AA

CUIL13TR00752AA

CUIL13TR00753AA

21. Install the lining and secure the lining with new clips in the positions indicated by the arrows in the figure to the side.

NOTE: The clips are mounted under pressure.

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Platform, cab, bodywork, and decals - Cab

22. Install the fan control connectors (1) onto the terminals on the rear of the control panel. 23. Install the wire connector (2) for the thermostat for the air conditioner onto the terminals on the control panel.

CUIL13TR00756AA

CUIL13TR00759AA

CUIL13TR00761AA

CUIL13TR00749AA

24. Install the heating control cable (1) on the control panel.

25. Install the two bolts (1) and (3) for the control panel (2) for the air conditioner on the lining of the roof. NOTE: Make sure that the inner fitting clips for the bolts (1) and (3) are in good condition and fixed in the right place.

26. Install the electrical connectors (1) on both columns. If necessary, see the wiring diagram in Wiring harnesses - Electrical schematic sheet 18 SH18 ROOF COMPONENTS (55.100).

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Platform, cab, bodywork, and decals - Cab

27. Install the power connectors for the heater (2) on the left-hand frame (1).

CUIL13TR00755AA

CUIL13TR00754AA

CUIL13TR00770AA

28. Install the three connectors (2) on the left-hand frame (1). If necessary, see the wiring diagram in Wiring harnesses - Electrical schematic sheet 18 SH18 ROOF COMPONENTS (55.100).

29. Install new clips in the positions indicated in the figure to the side and install the frames (1) and (2). NOTE: There are four clips on each frame. Two front and two rear. 30. Reconnect the battery negative lead.

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Index Platform, cab, bodywork, and decals - 90 Cab - 150 Cab - Raise . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab roof - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Cab roof - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

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Contents Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110

SERVICE Platform Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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Platform, cab, bodywork, and decals - Operator platform less cab

Platform - Remove 1. Disconnect the negative (-) battery cable from the battery. 2. Remove the frame canopy of the Roll Over Protective Structure (ROPS). Consult the procedures in Roll Over Protective Structure (ROPS) frame canopy Remove (90.114). 3. Remove the fixing pin (1) and remove the rod used to control the hydraulic lift from the rear.

LAIL11TL0619A0A

LAIL11TL0620A0A

LAIL11TL0621A0A

LAIL11TL0622A0A

4. Disassemble the respective fixing pins and disassemble both rods. If necessary, remove the rods from the platform as well.

5. Loosen the bolts (1) that fasten the breather tubes from the transmission and from the fuel reservoir to the mudguard. 6. Disassemble the remote control control valves.

7. Remove the clamps (1) that fasten the synchronized Power Take-Off (PTO) control lever to the gear box. 8. Disconnect the main levers from the end coupler.

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Platform, cab, bodywork, and decals - Operator platform less cab

9. Remove the PTO speed selection rod (1).

LAIL11TL0623A0A

LAIL11TL0626A0A

LAIL11TL0627A0A

LAIL11TL0624A0A

10. Move the cover away, loosen the fixing bolts and remove the reverse control lever (1).

11. Lower the cover, loosen the fixing bolt and remove the gear selection lever (1). 12. Lower the cover, loosen the fixing bolt and remove the range selection lever (2).

13. Remove the lock ring (1), remove the pin and disconnect the hand brake control cable.

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Platform, cab, bodywork, and decals - Operator platform less cab

14. Disassemble the differential lock rod front/rear articulation cotter pins and forks. 15. Disassemble the Lift-O-Maticâ&#x201E;˘ control cable from the hydraulics cover lever and remove the lever from the assembly. 16. Loosen the fixing knobs and remove the left-hand cover from the guard of the steering column. 17. Loosen the fixing nut and remove the clutch control rod. Remove the rubber cover and remove the rod from the hole. LAIL11TL0625A0A

18. Loosen the fixing knob and remove the right-hand cover (1) from the steering column. Then remove the throttle pedal cable. 19. Remove the hood. Consult the procedures in Hood Remove (90.100).

LAIL11TL0630A0A

LAIL11TL0638A0A

LAIL11TL0639A0A

20. Disconnect the three electrical connections (1).

21. Move and remove the connection (1).

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Platform, cab, bodywork, and decals - Operator platform less cab

22. Disconnect the engine tachometer cable (1) and remove the set support bolts (2).

LAIL11TL0642A0A

LAIL11TL0643A0A

LAIL11TL0640A0A

LAIL11TL0641A0A

23. Disconnect the two flexible hoses (1) from the steering cylinder. NOTE: Identify the components to facilitate assembly.

24. Disconnect electrical connections (1) and (2) from the fuel reservoir and brake cylinders. 25. Remove the tubes (3) from the brake cylinders and move the pressure sensors.

26. Disconnect the cable from the injection pump.

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Platform, cab, bodywork, and decals - Operator platform less cab

27. Loosen the rear bolts (1) securing the platform to the side casing (do this on both sides).

LAIL11TL0644A0A

LAIL11TL0645A0A

LAIL11TL0646A0A

28. Connect a hoist to the platform with two nylon ropes. Then place the ropes under tension.

29. Loosen the front bolts (1) that secure the platform to the support (do this on both sides). 30. Slowly raise the cab ensuring there are no connections, unions or parts interfering, then remove the platform and place it onto an adequate support base.

Next operation: Platform - Install (90.110) .

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Platform, cab, bodywork, and decals - Operator platform less cab

Platform - Install Prior operation: Platform - Remove (90.110) . 1. Insert the longer bolt in the inner front hole (on the reservoir side) on the left-hand platform assembly. Use two nylon ropes and a hoist to position the platform on the transmission and fasten the bolts. 2. Connect the throttle cable. 3. Connect the service brake control tubes to the respective cylinders and electrical connections to the brake oil reservoir to the pressure sensors. 4. Connect the steering tubes. 5. Connect and fasten the tachometer cable to the engine. 6. Make the electrical connections between the tractor platform and body. 7. Install the hood and the two gas cylinders. 8. Turn on the headlights. 9. Connect the clutch - gear box control rod and install the guards under the control panel. 10. Connect the Lift-O-Maticâ&#x201E;˘ control cable. 11. Connect the differential lock mechanical control rod. 12. Connect the hand brake control cable. 13. Install the gear box control levers. 14. Install the reverse control lever, if it exists. 15. Install the speed selection cable for the Power TakeOff (PTO). 16. Assemble the levers that control the PTO synchronized with the gear box. 17. Fasten the vent tube to the fuel reservoir. 18. Assemble the hydraulic lift control levers. 19. Install the canopy with two nylon ropes and the winch. 20. Connect the negative battery cable.

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Index Platform, cab, bodywork, and decals - 90 Operator platform less cab - 110 Platform - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Platform - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Operator protections - 114

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Contents Platform, cab, bodywork, and decals - 90 Operator protections - 114

SERVICE Roll Over Protective Structure (ROPS) frame canopy Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Falling Objects Protective Structure (FOPS) frame Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

(*) See content for specific models 47835583 21/10/2015

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame canopy - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Connect a pulley to the canopy (1). Use two nylon ropes and apply tension to the ropes.

LAIL11TL0617A0A

LAIL11TL0618A0A

2. Remove the bolts (1) that secure the canopy to the bracket. 3. Remove the frame canopy of the Roll Over Protective Structure (ROPS).

Next operation: Roll Over Protective Structure (ROPS) frame canopy - Install (90.114)

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Platform, cab, bodywork, and decals - Operator protections

Roll Over Protective Structure (ROPS) frame canopy - Install DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

Prior operation: Roll Over Protective Structure (ROPS) frame canopy - Remove (90.114) 1. With the aid of a pulley, position the canopy (1) over the Roll Over Protective Structure (ROPS).

LAIL11TL0617A0A

LAIL11TL0618A0A

2. Remove the bolts (1) that secure the canopy to the ROPS.

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Platform, cab, bodywork, and decals - Operator protections

Falling Objects Protective Structure (FOPS) frame - Install TL60E 12x4, 4WD, new cab [HCCZTL60CFC438464 - ] TL60E Without cab, 12x4, 4WD [ZDCL05524 - ] TL75E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC437744 - ] TL75E 12x4, 2WD, new cab [HCCZTL75CFC438464 - ] TL75E Without cab, 2WD, 12x4 [ZDCY12367 - ] TL85E 12x12, 20x12, 4WD, new cab [HCCZTL75CFC438464 - ] TL85E 12x4, 12x12, 2WD, new cab [HCCZTL85CFC437744 - ] TL85E Without cab, 2WD [ZEC134399 - ] TL85E Without cab, 4WD [ZDCL04468 - ] TL95E 12x12, 20x12, 4WD, new cab [HCCZTL95EFC438464 - ] TL95E Without cab, 4WD [ZDC112512 - ]

LA ---

1. Install the rear frame (5) on the tractor with the bolts. 2. Install the left-hand (2) arm of the canopy and the righthand (7) arm of the canopy (1) with the washer and the bolt (8). 3. Install the support (3) to join the arms installed with the washer and the bolt assembly (4). 4. Install the canopy (1) with the washer and the bolt assembly (6).

CUIL14TR01398AA

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Index Platform, cab, bodywork, and decals - 90 Operator protections - 114

(*)

Falling Objects Protective Structure (FOPS) frame - Install (*) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) frame canopy - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Roll Over Protective Structure (ROPS) frame canopy - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

See

content

for 47835583 21/10/2015

90.3 [90.114] / 6

specific

models

Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

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Contents Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124

SERVICE Pneumatically-adjusted operator seat Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Remove 1. Remove the rubber guards (1) and (3). Remove the bolts that hold the plate in place (2). NOTE: There are two bolts behind the operator seat. 2. Remove the entire operator seat assembly. NOTE: If you want to remove only the operator seat, without the plate (2), there are four mounting bolts on the seat rails.

CUIL13TR00822AA

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Platform, cab, bodywork, and decals - Pneumatically-adjusted operator seat

Pneumatically-adjusted operator seat - Install 1. Install the operator seat in its housing. 2. Install all the plate screws (1).

CUIL13TR00822AA

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Index Platform, cab, bodywork, and decals - 90 Pneumatically-adjusted operator seat - 124 Pneumatically-adjusted operator seat - Install . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Pneumatically-adjusted operator seat - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

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Contents Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100

SERVICE Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - Engine hood and panels

Hood - Remove DANGER Heavy objects! Lift and handle all heavy components using lifting equipment with adequate capacity. Always support units or parts with suitable slings or hooks. Make sure the work area is clear of all bystanders. Failure to comply will result in death or serious injury. D0076A

1. Remove the exhaust pipe. 2. Use a strap to lift the hood.

LAIL11TL0548A0A

CUIL13TRO0202AA

CUIL13TR00350AA

3. Disconnect the electrical connections (1) and (2).

4. Remove the gas cylinders (1) and (2) for raising the hood.

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Platform, cab, bodywork, and decals - Engine hood and panels

5. Remove the four bolts (1) and remove the hood.

LAIL11TL0551A0A

LAIL11TL0552A0A

LAIL11TL0553A0A

LAIL11TL0554A0A

6. Loosen the hood assembly (1) holding the bolts.

7. Loosen the bolts (1) of the hood central assembly.

8. Loosen the hood front assembly fixing bolts (1) and remove the assembly.

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Index Platform, cab, bodywork, and decals - 90 Engine hood and panels - 100 Hood - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102

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Contents Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102

SERVICE Side shield Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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Platform, cab, bodywork, and decals - Engine shields, hood latches, and trims

Side shield - Remove 1. Remove the bolt (1) from the engine side shield.

CUIL13TR00322AA

CUIL13TR00323AA

2. Remove the bolt (1) and remove the shield (2). 3. Repeat the procedure on the other side of the engine.

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Index Platform, cab, bodywork, and decals - 90 Engine shields, hood latches, and trims - 102 Side shield - Remove . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

47835583 21/10/2015 EN

SPECIAL TOOL INDEX Genuine 380000154 [Overload Revolving Stand Brackets] 380000617 [Dummy Injector] 380000303 [Cylinder Liner Pressure Check Kit] 380000232 [Rocker Wrench - used for valve clearance adjustment on 4.5L & 6.7L NEF Engines] 380000322 [Injection Pump Drive Gear Puller] 380000215 [Hand Pump Assembly for Valve Calibration] 380000228 [Dial Gauge (0 - 5 mm)] 380000228 [Dial Gauge (0 - 5 mm)] 380003211 [Syncronize (Timing) Tool] 380003211 [Syncronize (Timing) Tool] 380003211 [Syncronize (Timing) Tool] 380000293 [CLUTCH LEVERS ADJUSTMENT GAUGE] 380000293 [CLUTCH LEVERS ADJUSTMENT GAUGE] 293940 [Reverse Speed Pivor Remover] 380000549 [Slide Hammer] 293940 [Reverse Speed Pivor Remover] 380000549 [Slide Hammer] 299000 [Tractor Splitting Kit. Consists Of 299001, 299002, 299003] 299001 [Engine Section Of Splitting Stand US No 50817] 299002 [Transmission Section Of Splitting Stand US No 60296] 299003 [Rear Section Of Splitting Stand US No 60293] 299000 [Tractor Splitting Kit. Consists Of 299001, 299002, 299003] 299001 [Engine Section Of Splitting Stand US No 50817] 299002 [Transmission Section Of Splitting Stand US No 60296] 299003 [Rear Section Of Splitting Stand US No 60293]

Reference

PAGE

Engine - Remove

10.1 / 13

Engine - Compression test Engine - Compression test

10.1 / 20 10.1 / 20

Rocker arm - Adjust â&#x20AC;&#x201C; Clearance between the valves and rockers

10.2 / 6

Rotary injection pump - Remove

10.7 / 9

Rotary injection pump - Service instruction Delphi DP 150 injection pump

10.7 / 14

Rotary injection pump - Timing adjust Bosch injection pump

10.7 / 16

Rotary injection pump - Timing adjust Bosch injection pump

10.7 / 17

Rotary injection pump - Timing adjust Delphi DP 150 injection pump Rotary injection pump - Timing check Delphi DP 150 injection pump Rotary injection pump - Timing check Delphi DP 150 injection pump Clutch - Alignment

10.7 / 19

Clutch - Alignment

18.1 / 23

Mechanical transmission - Special tools

21.1 / 5

Mechanical transmission - Special tools Mechanical transmission - Disassemble

21.1 / 5 21.1 / 33

Mechanical transmission - Disassemble Creeper - Special tools

21.1 / 33 21.2 / 4

Creeper - Special tools

21.2 / 4

Creeper - Special tools

21.2 / 4

Creeper - Special tools

21.2 / 4

Reverser - Special tools

21.3 / 4

Reverser - Special tools

21.3 / 4

Reverser - Special tools

21.3 / 4

Reverser - Special tools

21.3 / 4

47835583 21/10/2015

10.7 / 21 10.7 / 21 18.1 / 23

Genuine 380000552 [Pressure Gauge 0 - 40 Bar] 380000552 [Pressure Gauge 0 - 40 Bar] 380000552 [Pressure Gauge 0 - 40 Bar] 380000279 [Seal Installer Tool For 50mm Piston Seal] 380000280 [Seal Installer Tool For 35mm Piston Seal] 380000279 [Seal Installer Tool For 50mm Piston Seal] 380000280 [Seal Installer Tool For 35mm Piston Seal] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000253 [FRONT DIFFERENTIAL BEARING PRELOAD ADJUSTMENT TOOL] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000252 [Front Axle Ring Nut Wrench] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000249 [Universal Pinion Installation Tool Kit]

Reference

PAGE

Electro-hydraulic control - Special tools

23.1 / 3

Front-Wheel Drive

23.1 / 6

Front-Wheel Drive

23.1 / 7

Four-Wheel Drive

23.2 / 3

Four-Wheel Drive

23.2 / 3

Four-Wheel Drive

23.2 / 13

Four-Wheel Drive

23.2 / 13

Powered front axle - Special tools

25.1 / 3

Powered front axle - Special tools

25.1 / 3

Powered front axle - Disassemble

25.1 / 13

Powered front axle - Disassemble

25.1 / 13

Powered front axle - Disassemble

25.1 / 13

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 4

Differential - Special tools

25.2 / 5

Front bevel gear set and differential - Remove

25.2 / 10

Front bevel gear set and differential - Remove

25.2 / 10

Front bevel gear set and differential - Depth adjust

25.2 / 12

Front bevel gear set and differential - Depth adjust

25.2 / 12

Front bevel gear set and differential - Depth adjust

25.2 / 12

Front bevel gear set and differential - Depth adjust

25.2 / 12

Front bevel gear set and differential - Depth adjust

25.2 / 12

47835583 21/10/2015

Genuine 380000249 [Universal Pinion Installation Tool Kit] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000600 [Bevel Pinion Shimming Adjusting Gauge] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000248 [Bevel Pinion Bearings Adjusting Guage] 380000249 [Universal Pinion Installation Tool Kit] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000268 [Bevel Pinion Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000252 [Front Axle Ring Nut Wrench] 380000257 [Bevel Gear Pinion Splined Retainer Deep Socket] 380000269 [Wheel Hub Bearing Ring Socket] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000265 [Swivel Housing Pin Pivot Puller] 380001143 [Front Axle Shaft to Swivel Housing Mounting Guide (Class 3)] 380000235 [Swivel Housing Torque Check Adapter] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000284 [Wheel Hub Seal Installer] 380000265 [Swivel Housing Pin Pivot Puller] 380000234 [Swivel Pin Bearing Outer Race Puller] 380000235 [Swivel Housing Torque Check Adapter] 380001143 [Front Axle Shaft to Swivel Housing Mounting Guide (Class 3)]

Reference

PAGE

Front bevel gear set and differential - Depth adjust

25.2 / 12

Front bevel gear set and differential - Adjust

25.2 / 14

Front bevel gear set and differential - Adjust

25.2 / 14

Front bevel gear set and differential - Adjust

25.2 / 14

Front bevel gear set and differential - Adjust

25.2 / 14

Front bevel gear set and differential - Adjust

25.2 / 14

Front bevel gear set and differential - Preload

25.2 / 16

Front bevel gear set and differential - Preload

25.2 / 16

Front bevel gear set and differential - Preload

25.2 / 16

Front bevel gear set and differential - Preload

25.2 / 17

Front bevel gear set and differential - Preload

25.2 / 17

Front bevel gear set and differential - Install

25.2 / 18

Front bevel gear set and differential - Install

25.2 / 18

Front bevel gear set and differential - Install

25.2 / 18

Differential - Install

25.2 / 21

Differential - Install

25.2 / 22

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Final drive hub, steering knuckles, and shafts - Special tools

25.3 / 3

Steering knuckle and king pin - Replace

25.3 / 5

Steering knuckle and king pin - Replace

25.3 / 6

Steering knuckle and king pin - Adjust

25.3 / 7

Steering knuckle and king pin - Adjust

25.3 / 7

47835583 21/10/2015

Genuine 380000235 [Swivel Housing Torque Check Adapter] 380000548 [Front Axle Planetary Reduction Hub Alignment Pins (M12 x 1.25)] 380000269 [Wheel Hub Bearing Ring Socket] 380000541 [Axle Pivot Pin Adaptor (M12 x 1.25) ] 380000549 [Slide Hammer] 380000549 [Slide Hammer] 380000541 [Axle Pivot Pin Adaptor (M12 x 1.25) ] 380000249 [Universal Pinion Installation Tool Kit] 380000253 [FRONT DIFFERENTIAL BEARING PRELOAD ADJUSTMENT TOOL] 583192 [Tool To Make For Adjusting The Assembly Position Of The Bevel Pinion Shaft] 50041 [Differential Block Sleeve Adjuster] 583192 [Tool To Make For Adjusting The Assembly Position Of The Bevel Pinion Shaft] 380000249 [Universal Pinion Installation Tool Kit] 380000253 [FRONT DIFFERENTIAL BEARING PRELOAD ADJUSTMENT TOOL] 380001113 [Final Drive Housing Lifting Bracket] 50114 [Final Drive Removal And Reassembly Tool] 50114 [Final Drive Removal And Reassembly Tool] 380001113 [Final Drive Housing Lifting Bracket] 50114 [Final Drive Removal And Reassembly Tool] 380001113 [Final Drive Housing Lifting Bracket] 380000552 [Pressure Gauge 0 - 40 Bar] 380000552 [Pressure Gauge 0 - 40 Bar] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor] 380000243 [Transmission Clutch Spring Compressor]

Reference

PAGE

Steering knuckle and king pin - Adjust

25.3 / 8

Wheel hub - Disassemble

25.3 / 11

Wheel hub - Disassemble

25.3 / 11

Non-powered front axle - Special tools

25.4 / 3

Non-powered front axle - Special tools Non-powered front axle - Remove Non-powered front axle - Remove

25.4 / 3 25.4 / 7 25.4 / 7

Differential - Special tools

27.2 / 4

Differential - Special tools

27.2 / 4

Differential - Special tools

27.2 / 5

Differential - Special tools

27.2 / 5

Bevel pinion - Depth adjust

27.2 / 7

Bevel pinion - Depth adjust

27.2 / 7

Differential - Install

27.2 / 16

Planetary final drive - Special tools

27.3 / 4

Planetary final drive - Special tools

27.3 / 4

Planetary final drive - Special tools

27.3 / 5

Planetary final drive - Special tools

27.3 / 5

Final drive housing - Disassemble

27.3 / 11

Final drive housing - Disassemble

27.3 / 11

Power Take-Off

31.1 / 13

Power Take-Off

31.1 / 15

Three-speed rear Power Take-Off

31.4 / 6

Three-speed rear Power Take-Off

31.4 / 19

Three-speed rear Power Take-Off

31.4 / 20

Three-speed rear Power Take-Off

31.4 / 21

Three-speed rear Power Take-Off

31.4 / 21

47835583 21/10/2015

Genuine 380000552 [Pressure Gauge 0 - 40 Bar] 380000552 [Pressure Gauge 0 - 40 Bar] DATAR Flow Meter [DATAR Flow Meter] DATAR Flow Meter [DATAR Flow Meter] 380000275 [Control Pilot Valve Seal Guard] 380000274 [Union for Checking Distributor Valve Seal] 380000218 [Union for Cylinder Safety Valve Calibration] 380000230 [Wrench For Cylinder Safety Valve Setting Ring Nut] 380000217 [Lift Relief Valve Adapter ] 380000266 [Lift Arm Speed Adjusting Pin Seal Installer] 380000275 [Control Pilot Valve Seal Guard] 380000275 [Control Pilot Valve Seal Guard] 380000274 [Union for Checking Distributor Valve Seal] 380000274 [Union for Checking Distributor Valve Seal] 380000274 [Union for Checking Distributor Valve Seal] 380000218 [Union for Cylinder Safety Valve Calibration] 380000215 [Hand Pump Assembly for Valve Calibration] 380000230 [Wrench For Cylinder Safety Valve Setting Ring Nut] 380000217 [Lift Relief Valve Adapter ] 380000215 [Hand Pump Assembly for Valve Calibration] 380000215 [Hand Pump Assembly for Valve Calibration] 380000224 [Hydraulic Lift Lifting Hook] 380000823 [100 mm Piston And Seal Installation Guide] 380000225 [110 mm Piston And Seal Installation Guide] 380000262 [RETAINER INSTALLER] 293839 [Control Link Needle Bearing Installer]

Reference

PAGE

Low pressure valve - Special tools

35.3 / 3

Regulated/Low pressure system - Pressure test

35.3 / 6

Remote control valve - Test

35.4 / 24

Remote control valve - Test

35.4 / 25

Three-point hitch control valve - Special tools

35.5 / 4

Three-point hitch control valve - Special tools

35.5 / 4

Three-point hitch control valve - Special tools

35.5 / 4

Three-point hitch control valve - Special tools

35.5 / 4

Three-point hitch control valve - Special tools

35.5 / 4

Three-point hitch control valve - Sectional view

35.5 / 11

Three-point hitch control valve - Sectional view

35.5 / 11

Three-point hitch control valve - Check

35.5 / 16

Three-point hitch control valve - Check

35.5 / 16

Three-point hitch control valve - Check

35.5 / 16

Three-point hitch control valve - Check

35.5 / 17

Three-point hitch control valve - Check

35.5 / 18

Three-point hitch control valve - Check

35.5 / 18

Three-point hitch control valve - Check

35.5 / 18

Relief valve - Pressure setting

35.5 / 24

Relief valve - Pressure setting

35.5 / 24

Relief valve - Pressure setting

35.5 / 24

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

47835583 21/10/2015

Genuine 380000231 [Wrench for Lift Pressure Relief Setting Ring Nut] 380000267 [Wrench for Arms Height Adjustment] 380000275 [Control Pilot Valve Seal Guard] 380000263 [Controlled Draft Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000237 [Rear Wheel Lifting Hook] 380000224 [Hydraulic Lift Lifting Hook] 380000237 [Rear Wheel Lifting Hook] 380000237 [Rear Wheel Lifting Hook] 293839 [Control Link Needle Bearing Installer] 293839 [Control Link Needle Bearing Installer] 380000823 [100 mm Piston And Seal Installation Guide] 380000225 [110 mm Piston And Seal Installation Guide] 380000262 [RETAINER INSTALLER] 380000264 [Position and Draft Control Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000267 [Wrench for Arms Height Adjustment] 380000264 [Position and Draft Control Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000263 [Controlled Draft Setting Tool]

Reference

PAGE

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Special tools

37.1 / 4

Rear three-point hitch - Remove

37.1 / 14

Rear three-point hitch - Remove

37.1 / 14

Rear three-point hitch - Disassemble

37.1 / 18

Rear three-point hitch - Disassemble

37.1 / 18

Rear three-point hitch - Assemble

37.1 / 19

Rear three-point hitch - Assemble

37.1 / 19

Rear three-point hitch - Assemble

37.1 / 20

Rear three-point hitch - Adjust of the position

37.1 / 23

Rear three-point hitch - Adjust of the position

37.1 / 24

Rear three-point hitch - Height adjust

37.1 / 25

Rear three-point hitch - Height adjust

37.1 / 25

Rear three-point hitch - Height adjust

37.1 / 25

Rear three-point hitch - Adjust – Constant effort

37.1 / 26

Rear three-point hitch - Adjust – Constant effort

37.1 / 26

Rear three-point hitch - Adjust – Constant effort

37.1 / 27

Rear three-point hitch - Adjust – Constant effort

37.1 / 27

Rear three-point hitch - Adjust – Constant effort

37.1 / 27

Rear three-point hitch - Adjust – Constant effort

37.1 / 27

Rear three-point hitch - Adjust – Constant effort

37.1 / 28

Rear three-point hitch - Adjust – Constant effort

37.1 / 28

Rear three-point hitch - Adjust – Constant effort

37.1 / 28

Rear three-point hitch - Adjust – Constant effort

37.1 / 28

Rear three-point hitch - Adjust – Constant effort

37.1 / 28

47835583 21/10/2015

Genuine 380000263 [Controlled Draft Setting Tool] 380000264 [Position and Draft Control Setting Tool] 380000263 [Controlled Draft Setting Tool] 380000224 [Hydraulic Lift Lifting Hook] 380000237 [Rear Wheel Lifting Hook] 380000618 [Steering Adapter Fitting] 380000281 [Rotoglyd Steering Seal Installer] 380000836 [Variable Power Steering Seal Installation Tool (Danfoss)] 380000836 [Variable Power Steering Seal Installation Tool (Danfoss)] 380000281 [Rotoglyd Steering Seal Installer] 380000281 [Rotoglyd Steering Seal Installer] 380000307 [Power Steering Rotor Locker Lever] 380000307 [Power Steering Rotor Locker Lever] 380000618 [Steering Adapter Fitting] 380003353 [Cab Lift Frame] 380003353 [Cab Lift Frame] 380003353 [Cab Lift Frame]

Reference

37.1 / 29

Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort

37.1 / 29

Rear three-point hitch - Adjust

37.1 / 30

Rear three-point hitch - Install

37.1 / 31

Rear three-point hitch - Install

37.1 / 31

Hydraulic control components - Special tools

41.1 / 4

Hydraulic control components - Special tools

41.1 / 4

Hydraulic control components - Special tools

41.1 / 4

Hydraulic control components - Troubleshooting

41.1 / 27

Power steering control valve - Assemble

41.1 / 21

Power steering control valve - Assemble

41.1 / 21

Power steering control valve - Assemble

41.1 / 22

Power steering control valve - Assemble

41.1 / 23

Steering circuit relief valve - Pressure test

41.1 / 26

Cab - Raise Cab - Raise Cab - Remove

90.1 / 4 90.1 / 6 90.1 / 13

Kit 380000292 [Clutch Centralizer - includes 380000635 and 380000636] 380000229 [Dial Gauge Holder Tool For Rotary Injection Pump Timing] 380000229 [Dial Gauge Holder Tool For Rotary Injection Pump Timing] 380000292 [Clutch Centralizer - includes 380000635 and 380000636] 380000292 [Clutch Centralizer - includes 380000635 and 380000636] 380000292 [Clutch Centralizer - includes 380000635 and 380000636] 380000292 [Clutch Centralizer - includes 380000635 and 380000636]

PAGE

Rear three-point hitch - Adjust â&#x20AC;&#x201C; Constant effort

Reference

PAGE

Engine - Install

10.1 / 15

Rotary injection pump - Timing adjust Bosch injection pump

10.7 / 16

Rotary injection pump - Timing adjust Bosch injection pump

10.7 / 17

Clutch - Remove

18.1 / 15

Clutch - Install

18.1 / 22

Clutch - Alignment

18.1 / 23

Clutch - Check

18.1 / 24

47835583 21/10/2015

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

47835583 21/10/2015 EN